Geometric simulation of process and tool design for high-speed whirling and high-speed whirl-milling of end mill geometries

Whirling is widely applied in the manufacturing of threaded components with high surface quality requirements, such as bone screws and precision lead screws. Due to favorable engagement conditions, the process is particularly suitable for hard-to-machine materials like titanium. Synchronized cyclic processes are increasingly used because they offer a high degree of geometric freedom. In synchronized high-speed whirling and high-speed whirl-milling, the rotational speeds of the workpiece and tool are synchronized according to the ratio of thread pitch to the number of cutting edges. This configuration allows for a significant reduction in process time compared to conventional whirling. This work investigates the geometric feasibility of manufacturing end mill geometries using high-speed whirling and high-speed whirl-milling. Tool and process design for one exemplary end mill variant are derived from geometric penetration calculations and the resulting process param eters for high-speed whirling and high-speed whirl-milling are compared. The simulation results indicate that both processes are fundamentally suitable for producing end mill geometries. ... mehrNevertheless, the present work is restricted to a geometric feasibility assessment. Experimental val idation is required to evaluate practical applicability, particularly with regard to cutting material selection, achievable surface integrity, and tool wear behavior.