Design and milling performance investigation of a new PCBN multi-edge ball milling and grinding composite tool

The structure and material of micro tools have a significant impact on their machining performance. To improving the machining performance and wear resistance of micro milling tools, a new PCBN multi-edge ball milling and grinding composite tool (ME-BMGT) with multi-edge and spherical flank is proposed. The micro milling experiment results show that, compared with the cemented carbide double-edged ball-end milling tool (OMBMT), the micro groove morphology machined by the ME-BMGT has grinding texture characteristics, the micro groove surface quality is better, and the burr height is smaller. The wear morphology shows that the wear form of ME-BMGT is adhesive wear, while the wear form of OMBMT is cutting edge fracture and adhesive wear. The ME-BMGT provides superior wear resistance.