Lightweight design of milling cutter with modified stiffness

The conventional milling cutter design is based on a solid body. A cutter designed in this way has a guaranteed rigidity, but at the expense of tool dynamics. Computational methods of designing reduce the mass of a cutter in locations with lower stress density. This approach increases stiffness relative to the weight of the cutter. This paper analyses the benefits of modifications in the design of a lightweight cutter. The design uses an envelope of a conventional milling cutter that is filled by walls. Each modification changes the elasticity in different directions. These changes are monitored by displacements at the centre of the cutting inserts under load. Simulations confirm that even a small weight gain can mean a significant increase in tool stiffness.