Angled Blisk Tool Assembly for Continuous Fracture Machining

The patent applies asymmetry by transitioning from a traditionally symmetric ball-nose end mill to an asymmetric cutting tool design. The new tool features an asymmetric cutting edge geometry that can accommodate complex, non-symmetric blade shapes in blisks. This asymmetric design eliminates the interference problems that occur when symmetric tools attempt to cut compound curves, allowing the tool to conform to the intricate geometries of turbine blades without creating unwanted material removal patterns.

The patent implements continuity of useful action by designing a cutting tool and process that maintains continuous contact with the workpiece during material removal. The asymmetric cutting edge geometry enables the tool to follow complex blade contours without lifting or interrupting the cutting action. This continuous cutting process eliminates the start-stop nature of traditional rotary milling, preventing heat buildup from repeated engagement and disengagement, and avoiding the plastic deformation and embrittlement that lead to workpiece fracture.

The patent applies parameter changes by fundamentally altering the cutting process parameters. Instead of using traditional rotary milling with rotating tools and intermittent cuts, the invention employs controlled fracture machining with linearly moving asymmetric tools that apply impact forces to the workpiece. This parameter change transforms the material removal mechanism from gradual plastic deformation to controlled fracture, achieving volumetric material removal rates that are orders of magnitude higher than conventional methods while still being implementable with modified existing machinery.