Research on design and milling performance of unequal gradient helix and variable pitch end mill

It is difficult to obtain excellent surface quality and dimensional accuracy of the low-rigidity frame and beam parts made by titanium alloy, due to the obvious vibration and large elastic deformation during side milling. The variable helix and pitch cutting tool is usually used to reduce vibration, which does not consider the unequable stiffness in the milling area. Therefore, the concept of Unequal Gradient Helix and Variable Pitch (UGHVP) is proposed in this research. The helix angles of the UGHVP vary with the stiffness of the milling area position, which will lead to milling forces and vibration decreasing as the stiffness weakens. As a result, the surface quality and dimensional accuracy will be increased, of which the advantages are analyzed. The mathematical models of the UGHVP circumferential cutting edges and groove sections are derived, which provide theoretical support for tool grinding. The models are visualized by numerical simulation. Finally, the comparison experiment with the conventional variable helix and pitch end mill was completed by side-milling the designed feature samples. The results showed that the milling forces perpendicular to the milling surface by the UGHVP were smaller and less fluctuating, which could obtain less elastic deformation theoretically. The milling vibration was smoother, especially when cutting in and out. Besides, the larger the axial depth of cut, the more obvious the superior performance of the UGHVP tool. Better surface quality and dimensional accuracy were obtained, which proved the excellent performance of the UGHVP.