Effect of the helix angle of router bits on chip formation and energy consumption during milling of solid wood

The effect of the helix angle of a router bit on chip formation and electric energy per volume (specific energy) under different feed speeds and cutting depths during the milling of maple and China fir by a computer numerically controlled (CNC) router was investigated. The peripheral cutting edge of router bits were custom-made at helix angles of 0°, 2°, 4°, 6°, and 8°. The feed speed varied from 600 to 4800mm/min, and the depths of cut were set at 1,2,3,4, and 6mm. The chips were classified by sieving into a flake type, a splinter type (5 and 10 mesh), a flow type (20 and 40 mesh), and a granule type (< 40 mesh). As the feed speed and the cutting depth increased for the five router bits, more chips of the flake type and the splinter type were produced. However, the number of granule-type chips under the larger helix angle was reduced. The energy per volume removed (specific energy) increased with the feed speed and the depth of cut while milling maple and China fir. More specific energy per cubic centimeter was consumed under the lower feed speeds and the smaller depth of cut. The specific energy can be expressed as a negative power function of the feed speed or the cutting depth for maple and China fir.