Energy-saving Optimization Of Solid End Mill Cutting Edge Based On Floyd Algorithm And Research On Chip-ejection Analysis

End milling cutters, also known as end mills, are widely used and complex-shapedrotary cutters in modern mechanical manufacturing industry. Due to the inadequateunderstanding, the end mills which are self-designed by our country at present are still inthe state of simple geometric design relys mainly on experience. For different conditions,using standard spiral cutting edge in cylindrical surface may bring about high millingforce, a low machining efficiency and huge waste of energy. As for this problem, thispaper aims to improve the end mill performance and reduce energy consumption. Theauthor advances a method for the optimum design of the helical end mill cutting edgedistribution by using Planar Displaying Method, Linear Synthesis Method and Non-linearSynthesis Method (considering chip-ejection interference of different segments along thecutting edge) of Elementary Cutting Tools (ECT), and the Shortest Path Algorithm. Themain contents of this paper are:First, through the known profile of the helical end mill cross section, the parametricequations for rake face, flank face and helical cutting edge were established. With the helpof Planar Displaying Method and kinematic analysis, a general model was developed tocompute the cutting angles of an end mill with arbitrary curved cutting edge.And, based on the empirical cutting forces model which developed by obliqueturning experiments and cutting angles model above, the paper established a predictingmodel for milling power of an end mill with arbitrary curved cutting edge.Then, the rake face of ordinary helical end mill was meshed and the adjacency matrixwas acquired. In order to obtain the minimum milling power, Floyd Algorithm was used torealize the curve research. The results show that, compared with ordinary helical end mill,the milling power reduced by25.46%on average for the optimized end mill.At last, four groups of turning experiments were designed in order to explore theeffect of chip-ejection direction and velocity interference, the appearance of chip splittingon cutting forces with different rake angles and cutting edge angles of V-shaped cuttingtools. Based on the measured cutting forces, a model for main cutting force consideringchip-ejection interference was established. A method based on Genetic Algorithm forcalculation of Non-free Cutting Coefficient of the end mills was proposed. The Non-freeCutting Coefficient is1.17and1.06for ordinary end mill and optimized end millrespectively. Taking the performance of chip-ejection in consideration, the decreasing rateof milling power of the optimized end mill is30.49%, which indicates the superiority ofoptimized end mill on chip-ejection performance.