Influence of micro- and macroscopic tool features and errors within one batch in end milling

Among other things the tool geometry influences the accuracy of the machined part, the chip formation and the process forces in end milling. The tool geometry can be divided into two different features: the micro and the macro geometry. The micro geometry describes the shape of the cutting edge and can influence the process forces, tool life and surface quality. The macro geometry describes the general specification of the tool as well as the runout. The runout can also affect process forces, tool life and the surface topography. This study shows that the micro and macro geometry of end mills of the same specification can vary significantly in one batch. This also has an influence on the process forces and resulting surface topography in end milling processes.