Method of increasing the rigidity and vibration resistance of non-rigid end mills in processing slot grooves

   The article addresses the pressing challenge of machining deep slot grooves and narrow cavities with widths of 3 mm or less in components used in aerospace and power engineering.

   Particular emphasis is placed on the insufficient rigidity and tendency to vibrate in elongated solid carbide end mills, especially when the length-to-diameter ratio L/D ˃ 5.

   These vibrations degrade surface quality, accelerate cutting edge wear, induce runout and often lead to tool failure. The authors analyse existing solutions and propose a new method to enhance tool rigidity: the use of a supporting steady rest (steady). This device acts as an additional support for the end mill, significantly increasing its stiffness and suppressing vibrations. The authors present results from mathematical modeling of the static rigidity of the tool system. One of the key advantages of this method is its technological simplicity and the ability to integrate it into existing CNC machines without major equipment overhaul. Unlike active damping systems, the method does not require complex electronics or specialized software. It enables the machining of deep, narrow slots even under highly unfavorable width-to-depth ratios-a task previously considered technologically challenging. Moreover, increased rigidity improves tool life and allows for higher cutting parameters, boosting productivity. This approach is particularly promising for machining parts made from heat-resistant alloys, where conventional milling techniques face significant limitations.

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