Structure Optimization of Variable Pitch Helix End Mills Based on FEM Simulation

Chatter is one of the main factors that affects the manufacturing quality and limits the productivity during milling. If properly selecting mills with variable pitch distribution, the chatter may be reduced. If mills have sufficient rigidity, its vibration resistance will be improved extremely. The paper summarizes the effects of helix angles, pitch angles distribution on the maximum stress, the maximum strain based on FEM simulation, the result of simulation can offer theoretical instructions to optimize and select the optimal mills based on intensity and rigidity.