The influence of end mill helix angle on high performance milling process

The results of experimental research on the influence of the helix angle on high performance milling of AlZn5.5MgCu alloy are presented. End mills with a wavy shape of a cutting edge, dedicated to rough high performance machining, were used. The helix angle was changed in the range of 20° to 50° with a step of 5°. During the milling tests, three cutting force components were measured. After each test cutting, chips were collected and analyzed. A recording of the chip evacuation process using a high-speed camera was also conducted. The influence of the helix angle on cutting force components was determined and the mathematical models of the forces were calculated. The significance of coefficients in the obtained equations was analyzed as well. The recorded images of the chip evacuation were analyzed. The displacement and the angle of the chip evacuation were determined. Based on the analysis of the selected images the impact of the helix angle on the direction and evacuation velocity of chips was determined. The size and shape of the obtained chips was also analyzed.