The effect of cutting edge sharpness on cutting characteristic of polycarbonate

Abstract

Polycarbonate is used in various fields because it exhibits high-impact resistance and light-weight properties. Products requiring high flatness are made using an end mill. When the cutting edge of an end mill becomes dull, the surface quality worsens. This is a serious problem. In this experiment, sharp and worn tools were prepared to investigate the effects of an edge’s sharpness on the cutting characteristics of polycarbonate. The cutting force was measured, and the finished surface was observed. When the sharpness of the cutting edge was changed from 1 to 12 µm, the cutting force increased 20 % and the quality of the finished surface greatly worsens. In conclusion, small wear of a cutting edge, e.g. within 11 lm, degrades a surface’s finish and transparency.