Shape design optimization of a flat endmill tool

Abstract Among the many possible metal‐cutting processes, milling is regarded as one of the most widely applied processes to machine different engineering materials productively. During the milling process, there is relative motion between the endmill tool and the workpiece. Energy is required to drive the cutting force used by the tool in separating the chips from the workpiece. Several studies have focused on the effects of milling process parameters on the cutting force, for instance by varying the cutting parameters, machining properties and the extent of cooling/lubrication. Other studies have explored the influence of tool geometry and material properties on the cutting force. Results from these studies have brought about improvements in the design of milling machinery and tools. The current study presents a novel automated approach for tool geometry optimization which is fully coded in Matlab. An automated and parametrized endmill design procedure was created featuring input parameters such as rake angle, relief angle, clearance angle and helix angle, all of which have been shown, through numerous studies, to influence cutting forces. The parameters were here used to generate the shape profile for one cutting edge of a flat endmill. This cutting edge profile is next copied and rotated, as per the design's pitch angle, to form the complete set of cutting flutes for the flat endmill. Next, the surface defined by the completed profile is meshed using quadrilateral elements. The 3D endmill design is then formed by extruding, and twisting as per the helix angle, this quadrilateral mesh to form a solid hexahedral mesh. Finally, an automated iterative optimization process was defined, featuring the above parametrized design process coupled with Abaqus‐based finite element simulation of the milling process. The expected result is that the proposed optimization procedure will be able to identify the endmill design parameters which minimize the cutting force. At the completion of the optimization, a minimized maximum resultant cutting force value is obtained from using the newly optimized endmill. The resultant cutting force was reduced by 17.6%. It is anticipated that the automated design, meshing and simulation‐driven optimization approach is generalizable to other tool design variations.