Research on distribution position of chip-split groove of discrete-edge end mills based on structural dynamic stability

The machining of aerospace deep cavity parts was prone to issues such as chatter. Currently, discrete-edge end mills are commonly employed in milling these parts, yet the vibration reduction mechanism of the cutter and the rationality of the distribution position of the chip-split groove have not been systematically studied. Consequently, a design method of distribution position of chip-split groove of discrete-edge end mill was proposed. Initially, the correlation between the discrete parameters of discrete-edge end mills and the eigenvalue of cutting vibration was examined to elucidate how the structural characteristics of discrete-edge end mills impact vibration. Subsequently, the impact of discrete-edge end mill structure, tool-work contact system, and cutting parameters on vibration was sequentially assessed. The effect of discrete parameters on the dynamic characteristics and cutting forces of the end mill was investigated, and the vibration reduction mechanism of discrete-edge end mill was revealed. Furthermore, the distribution position of chip-split groove of the discrete-edge end mill was optimized based on the Improved Grey Wolf Algorithm (I-GWO). The optimized parameters were as follows: a width of 1 mm, a total of 4 grooves, arranged alternately with varying density. Finally, the design method of distribution position of chip-split groove of discrete edge end mill was proposed, and the effectiveness of the method was verified by experiments. This method serves as a foundational reference for the design and production of discrete-edge end mills.