Multi angle characteristic description of end mills

In the tool industry, optical measurement is the key to success from both design and tool usage perspectives. Optical profilometers provide valuable information to manufacturers, helping them optimize their tools and processes.

A key application of optical measurement in tool manufacturing is the characterization of cutting tool dimensions to ensure optimal performance and long lifespan of the tool. In addition to size characterization, roughness measurement is also meaningful for predicting how well the cutting material will be discharged from the tool. These pieces of information are crucial for preventing clot formation or overheating during tool use.

Optical measurement systems can also provide local measurements to help identify potential cutting tool issues. For example, these systems can detect incisions or coating peeling, indicating that the tool needs to be replaced or repaired.

It is worth noting that these characterizations can be on very different orders of magnitude. For example, the size measurement of common cutting tools is usually in the millimeter range, while the evaluation of cuts or roughness is usually in the micrometer scale. However, now only one configuration is needed: Sensofar system, S neox Five Axis， Paired with Digital Surf software, SensoMAP。

Figure 1 shows the complete 3D measurement of an end mill taken using S Neox Five Axis. This measurement provides a complete view of the surface of the end mill, allowing for accurate analysis and evaluation.

3D Form Acquisition

Optical measurement systems like Sensofar's S neox Five Axis are crucial for characterizing various components and optimizing manufacturing processes in the tool manufacturing industry. The S Neox Five Axis system can capture the entire 3D shape of an object, including end mills, and provide high precision and accuracy.

A key feature of the S Neox Five Axis system is its rotating module, which allows for complete measurement of sample morphology. This feature is particularly useful in the tool industry, where precise measurement of cutting tools is crucial for achieving optimal performance.

In particular, its Shell module allows for extracting information from grid data at various levels.

The Shell module of SensoMAP software is a powerful tool that enables users to extract size and roughness information by navigating from grid data to terrain data, and then to contour data. This module provides an effective means of obtaining valuable insights from the acquired data.

Size Analysis

In our analysis, we conducted multiple measurements using parameterized contours generated from shell data to comprehensively understand the geometric shape of the end mill.

The first measurement involves extracting cross-sectional measurements perpendicular to the cutting axis of the end mill at multiple positions along the slot length (as shown in Figure 2). In this way, we can determine whether the tool maintains a consistent outer diameter throughout its entire length. In addition, we calculated the concentricity between the inner and outer circles to check for tool eccentricity.

Figure 2 Cross sections perpendicular to the tool axis are taken at 1mm intervals to check the uniformity of the groove diameter.

The second measurement aims to check the pitch of the spiral. To achieve this goal, we will load the tool into a cylinder and unfold it. Next, we extracted a contour perpendicular to the helix angle and measured the pitch (Figure 3). This measurement provides valuable insights into the geometry of the end mill and ensures its optimal performance.

Figure 3. An unfolded tool image is displayed on the right, and pitch measurement is shown on the left

Roughness analysis

The surface accuracy of the edges plays a crucial role in determining the results. Therefore, we use the previously developed data to take a contour on the groove and calculate the roughness parameter according to ISO 4278.

In this way, we ensure that the final component will have clean edges, rather than rough edges that may have a negative impact on the quality and performance of the final product.

Figure 4 shows the roughness measurement of one of the cutting edges of the tool. This measurement provides information about surface texture and can help determine the degree of tool wear

In summary, using advanced techniques and software (such as those used in this analysis) to measure the surface roughness of edges is crucial for achieving optimal surface accuracy and ensuring that the final product meets the required specifications.

Peeling evaluation of cutting tools

One of the most promising features of cutting tools is their coating, which has a significant impact on their durability and ability to resist high-pressure processes. It has been proven that coated cutting tools have a longer service life and better performance than uncoated tools. However, coating peeling is a major concern and may significantly affect the performance and durability of the tool.

Fortunately, SensoMAP's Shell module provides an excellent solution to this problem by making it possible to extract terrain from the grid (Figure 4).

By utilizing particle analysis, we can focus only on the area where delamination occurs and determine the extent of damage. This allows us to understand the size of the delamination area and determine whether it is limited to the coating or if some material is missing due to fragmentation.

Figure 6 shows the automatic detection function of the particle detection module using SensoMAP for peel evaluation. This technology allows for quick and accurate detection of any particles or fragments on the surface of end mills, which may affect their performance.

By identifying the degree of coating peeling and fragmentation, we can take appropriate measures to ensure that the tool remains in optimal condition and fully utilizes its potential.

Integrating S Neox Five Axis and SensoMAP has been proven to be a tool application*Solution. The S Neox Five Axis combines three different measurement techniques and a rotating module, making it a tool in the process of tool characterization***Tools. In addition, SensoMAP provides a comprehensive analysis tool for the shell.

The combination of SensoMAP and S Neox Five Axis enables us to describe the size, roughness, and peeling defects of end mills. With this innovative technology, manufacturers can achieve****With high precision and accuracy, it is possible to produce high-quality products that meet the demands of today's market.