Ball End Mill Gash Depth Layout for Chip Clogging Control
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Solution Overview
Problem
Ball end mills experience chip clogging in gashes adjacent to end cutting edges, particularly with multiple cutting edges, leading to compromised machining surface accuracy due to reduced gash volume and increased cutting edge length.
Innovation Solution
A ball end mill design featuring end cutting edges with varying lengths and corresponding gash depths, where the first end cutting edge has the longest length and deepest gash, followed by the second and third edges with shorter lengths and depths, respectively, to enhance chip discharging properties and prevent clogging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the number of end cutting edges is increased to six or more, then cutting performance is improved, but chip clogging occurs in the gashes
Solution Approach 1:
The patent applies local quality by making each gash have a different depth corresponding to its adjacent end cutting edge. The first gash (adjacent to the longest end cutting edge) has the greatest depth, the second gash has intermediate depth, and the third gash (adjacent to the shortest end cutting edge) has the least depth. This localized differentiation ensures that each gash has sufficient volume to discharge chips generated by its specific cutting edge, preventing chip clogging while maintaining high cutting performance with multiple edges.
2Length of moving object
If the cutting edge length is increased, then machining capability is improved, but gash volume decreases leading to chip clogging
Solution Approach 1:
The patent applies parameter changes by varying the depth parameter of each gash to compensate for the reduced gash volume caused by longer cutting edges. Specifically, the first gash has a greatest depth, the second gash has an intermediate depth, and the third gash has the least depth. This parameter differentiation ensures that each gash maintains sufficient volume for chip discharge despite the longer cutting edges, thereby preventing chip clogging while preserving enhanced machining capability.
Data Source
AI summary
A ball end mill according to the present invention includes an end mill body which is formed in a shaft shape, a plurality of convex arcuate end cutting edges which are disposed on a tip portion of the end mill body at intervals around an axis and form a hemispherical shape such that a rotational locus around the axis has a center on the axis, and a plurality of gashes which are respectively disposed to be adjacent to the plurality of end cutting edges in an end mill rotation direction around the axis. The plurality of end cutting edges includes a first end cutting edge longest among the plurality of end cutting edges, a second end cutting edge which is adjacent to the first end cutting edge in the end mill rotation direction and a third end cutting edge which is adjacent to the second end cutting edge in the end mill rotation direction.