Preparation of asymmetrical cutting edge geometries on micro end mills using pressurized wet abrasive jet machining for hard micromachining of AISI M3:2

Cutting edge preparation is an established approach in the field of machining technology for optimizing the performance of cutting tools. However, the potential of asymmetric geometries has not yet been sufficiently utilized for filigree micromilling tools. In this regard, the study presents investigations on the adjustment of asymmetric microgeometries through the design of the pressurized air wet abrasive jet machining (PAWAJM). The study features results regarding the design of the preparation process as well as subsequent application tests in a hard micromilling process of the hardened high-speed steel AISI M3:2. The application tests focus on the effect of the conditioned cutting edge on the process forces and the surface quality as well as the tool life. The results show that asymmetrical microgeometries with small average cutting edge rounding and a form-factor of K > 1.2 can be achieved by PAWAJM. Machining tests revealed a potential reduction of the wear development and process forces for modified tools with low cutting edge rounding and asymmetrical microgeometry.