Helix angle

Abstract: The mechanics of cutting with helical ball-end mills are presented. The fundamental cutting parameters, the yield shear stress, average friction coefficient on the rake face and shear angle are measured from a set of orthogonal cutting tests at various cutting speeds and feeds. The cutting forces are separated into edge or ploughing forces and shearing forces. The helical flutes are divided into small differential oblique cutting edge segments. The orthogonal cutting parameters are carried to oblique milling edge geometry using the classical oblique transformation method, where the chip flow angle is assumed to be equal to the local helix angle. The cutting force distribution on the helical ball-end mill flutes is accurately predicted by the proposed method, and the model is validated experimentally and statistically by conducting more than 60 ball-end milling experiments.

Abstract: The paper presents expressions for semi-empirical mechanistic identification of specific cutting and edge force coefficients for a general helical end mill from milling tests at an arbitrary radial immersion. The expressions are derived for a mechanistic force model in which the total cutting force is described as a sum of the cutting and edge forces. Outer geometry of the end mill is described by a generalized mathematical model valid for a variety of end mill shapes, such as cylindrical, taper, ball, bull nose, etc. The derivations follow a procedure originally proposed for a cylindrical end mill. The procedure itself is improved by including the helix angle in evaluation of the average edge forces. The resulting expressions for the specific force coefficients are verified by simulations and experiments.

Abstract: Thermo-mechanical equations were developed from machining theory to predict heat generation due to drilling and were coupled with a heat transfer FEM simulation to predict the temperature rise and thermal injury in bone during a drilling operation. The rotational speed, feed rate, drill geometry and bone material properties were varied in a parametric analysis to determine the importance of each on temperature rise and therefore on thermal damage. It was found that drill speed, feed rate and drill diameter had the most significant thermal impact while changes in drill helix angle, point angle and bone thermal properties had relatively little effect.