An investigation of wear in single-tooth and multi-tooth milling

Abstract In the last 25 yr investigations in milling have indicated that there is a difference in tool life depending upon the different number of teeth in the cutter. This paper shows that tool life is a nonlinear decreasing function of the number of teeth in the cutter. This function can be represented by a polynominal. Both the impact and the thermal effect on tool life were investigated. It was found out that the impact of the tooth entering the workpiece does not have a significant effect on tool life when two teeth are cutting simultaneously. However, increasing the number of teeth, causes the workpiece and the cutter temperature to increase, which in turn causes a decrease in tool life. This is explained by introducing the heat generated ratio in milling as a function of number of teeth. The effect of the number of teeth in the cutter on tool life depends on cutting speed, feed per tooth, and stiffness of the workpiece-tool-machine system. The practical results of this work is a proposal to use a three-tooth cutter instead of a single-tooth cutter, as is the wide spread practice, to predict the behaviour of the multitooth cutter in tool life testing.