Analysis and design of PCD milling tool for machining copper alloy materials

The geometry of the Polycrystalline Cubic Diamond (PCD) milling cutter is redesigned for machining copper alloy parts of power generation units. A unit cutting force model was established based on the measurement data of single cutting edge orthogonal machining to calculate the cutting force in specific sections of the cutter. The strength and rigidity of the cutting tooth is verified according to the calculation results. In practical production, it is found that the new PCD milling tool contains more space volume for chip curling. Therefore the tool wear is reduced significantly and the tool life is improved about 100 times.