Flank milling of compliant workpieces with chamfered tools

The use of chamfered tools is widely spread in cutting processes. Prior investigation show, that a chamfer on the rake face of a milling tool can increase the stability of cutting processes significantly due to a contact between the chamfer surface and the workpiece and the resulting damping forces. In addition to higher process stability, it is possible that the chamfer shows positive effects on the machined surface as well. A sufficient chamfer length can cut off the feed marks on the machined surface, but also damping effects on the process vibrations can lead to a better flank surface when milling compliant parts or tools as well. This paper describes an approach of simulation of machining of the flank surface with consideration of the chamfer geometry. In the experimental and simulative investigations it was found that by the reduction of extensive workpiece vibrations, the chamfer does have positive effect on the flank surface quality due to a contact between the chamfer and the workpiece. Furthermore, this contact does apparently occur earlier than a theoretical consideration would predict from the kinematics of the process. With increase of the chamfer length on the other hand, also augmented appearance of smearing effects on the surface, which decrease the surface quality, was observed.