Acta Universitatis Sapientiae Electrical and Mechanical Engineering, 3 (2011) 93-104 Study of the Edge Profile Variation Caused by the Re-sharpening by Profiled Milling Heads with Cutting Inserts Márton MÁTÉ, Dénes HOLLANDA Department of Mechanical Engineering, Faculty of Technical and Human Sciences, Sapientia Hungarian University of Transylvania, Tg. Mureş e-mail: mmate@ms.sapientia.ro, hollanda@ms.sapientia.ro Manuscript received October 04, 2011; revised December 18, 2011. Abstract: The paper presents the calculus of the cut profile and the variation of this caused by the re-sharpening, that appears by a special profiled milling head construction, that uses cutting inserts. The advantage of the proposed milling head versus the classical concave profiled milling disk is evident, if considering the repartition of the cutting speed vector and the chip forming and exhausting conditions. The cutting insert’s rake face is plain. Its relief face is a part of a common thorus realized by grinding. The insert occupies two distinct positions in the body of the tool: one for cutting and the other one for re-sharpening. Indexed positions are ensured through conical holes and corresponding slotted head sets. The re-sharpening can be done on the rake face or on the relief face. In both cases a minor profile error occurs but the profile is kept in the limits of the tolerance. This paper discusses the definition of the profile error and its dependence on the angular setting parameters and the number of the re-sharpening. The final conclusion is that the classical concave profiled milling disk can be replaced with the proposed variant. Keywords: Profile milling, profiled milling head profile error, inserts, geometry. 1. The assembly of the profiled milling head Profiled milling, especially in cases of convex profiles, is a difficult operation. The classical concave profiled disk mills present low rigidity on the teeth base [2, 3, 4, 5] and as a consequence, the cutting speed and feed cannot be set to high values. The productivity of operation is low and the surface roughness, due to the small rake angle values in most of the cases results just on the limit. Profiled disc mills are rather expensive due to the relieving operation.