End Milling of Elastomers—Fixture Design and Tool Effectiveness for Material Removal

Abstract

This paper describes the machining of elastomers using sharp, woodworking tools and the machining of cryogenically cooled elastomers. Due to the lack of information on tool selection for elastomer machining, a set of thirteen tools that cover different sizes and tool geometries and materials was used in this study. Fixture design was found to be critical in machining of elastomers because of its relatively low elastic modulus. The cutting force created during machining can generate significant deformations in the elastomer workpiece. The finite element technique is used to analyze the structural stiffness of the elastomer workpiece under different geometric configurations. The effective stiffness is defined to quantify and compare the stiffness of elastomer workpiece machined by different tool sizes. The cleanliness of the groove machined by end milling is investigated. Use of some down-cut end-milling tools effectively removed the elastomer material at room temperature and generated a clean groove. The tool configuration and part fixturing are identified as the two most important variables that affect the cleanliness of machined grooves. Cooling the elastomer workpiece by solid carbon dioxide (dry ice) to about −78.6°C improved the machined surface finish.