Modern high-value manufacturing relies heavily on solid carbide end mills for finishing critical components. The intricate geometry of these cutting tools plays a crucial role in machining success. Optimizing end mill design requires the precise definition of various parameters to ensure efficient machining. This research presents a novel CAD-based framework that empowers designers with the ability to create and optimize solid end mills. Tool parameters such as tool diameter, rake angle, helix angle, and the number of teeth are used as input variables from the designer to influence the tool overall design.

The framework facilitates the design of variable helix angle tools, renowned for their stability during machining operations. It leverages the automation capabilities offered by the Application Programming Interface (API) within the selected CAD platform. The solid geometry produced through the framework would allow for the accurate representation of cutting tools that can be further exploited in FEA and CFD simulations of machining applications. The API-based approach enables users to define specific criteria and achieve a comprehensive optimization of tool geometries. The resulting geometries are then compared with established industry standards from leading vendors, providing valuable validation. Moreover, the effect of key design variables on the geometry of the cutting tool is investigated.