Research On Structural Optimization Of PCD Micro End Tool

Design of micro end tool is one of the key technologies of micro-milling. This paper concentrateson improving the strength of PCD micro end tool. The FEM and experiment method was used to theresearch of micro-milling force, burr and strength of tool. The structure of PCD micro end tool wasoptimized based on the selection of rake angle of main cutting edge. The main content in this papercan be summarized as follows:1. On the basis of structural analysis of simple polyhedron structure micro end tool, this paperpresented an optimize method for the PCD micro end tool.2. The micro-milling force, micro-milling burr and strength of PCD micro end tool wasresearched by the method of FEM. The results indicated that a small negative rake angle of maincutting edge (about-10°) can improve the stiffness of micro end tool and avoid the substantial rise ofmicro-milling force and worsening of the micro-milling burr.3．A micro-milling force acquisition and processing system was designed and realized, whichincluded a design of parallel high frequency dynamometer fixture and a development of signalacquisition and processing software based on LabVIEW.4. Micro-milling experiment was carried and result proved that the large negative rake angle ofmain cutting edge would bring the substantial rise of micro-milling force and worsening of themicro-milling burr. But a reasonable small negative rake angle of main cutting edge would not bringsubstantial rise of micro-milling.