Numerical optimisation of bonded joints for the manufacture of edge milling tools

•A bonded joint construction for the manufacture of edge milling tools was numerically studied.•The main stresses acting on the adhesive layer of the tool were found to be normal stresses.•The angle of the bit was the most relevant design parameter, leading to improved shear behaviour.•No failure was detected for the maximum design load.•The suitability of this joining technique for the practical application was demonstrated. Edge milling tools for processing wood are currently assembled using brazing or fastening, joining the cutting insert to the tool body. However, the demand for lighter tools has led to a growing interest on changing this process to adhesive bonding. To determine the performance of the joint a cohesive zone model (CZM) was implemented, recurring to ANSYS® MechanicalTM. To optimise its geometry, a parametric simulation was performed using a simplified single insert model of the full milling tool. Due to the large number of design points, a two-step approach was adopted, focusing on optimising certain parameters in each stage. For the loading condition, a rotational velocity test under overspeed condition, required by the relevant safety standard, was performed. Finally, in terms of output, the stresses generated, as well as differences in cost or manufacturing processes compared to the already commercialised tool configuration were analysed. The developed model highlighted the large safety factor present in the original, base-line design, demonstrating that adhesive bonding can lead to a highly durable and resistant milling tool. The developed model also allowed to optimise some of the key design parameters, while providing paths for minimising the tool’s manufacturing cost and ensuring maximum performance.