Textured Ball End Mill Tip to Reduce Swarf Restraint
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Solution Overview
Problem
The existing ball end mills face limitations in contact with workpieces, leading to reduced tool lifetime and processing efficiency due to issues like swarf restraint and increased contact resistance.
Innovation Solution
The tool features a tip end portion with a surface comprising multiple protrusions, first recesses formed by adjacent protrusion contact, and second recesses either inside or between protrusions, optimized in terms of depth, length, and area ratio, made of nano-polycrystalline diamond or binderless cubic boron nitride, which are formed using laser irradiation to enhance contact and reduce wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the tool surface is made smooth and continuous, then the contact area with workpiece is increased, but swarf restraint and contact resistance increase leading to reduced tool lifetime
Solution Approach 1:
The tool surface is segmented into multiple protrusions and recesses instead of being smooth and continuous. This segmentation creates a textured surface that reduces swarf restraint and contact resistance while maintaining adequate contact area for effective cutting operation
Solution Approach 2:
The surface is given non-uniform local quality through the strategic arrangement of protrusions and recesses. Different regions of the surface have different properties - protrusions provide cutting edges while recesses reduce contact resistance and prevent swarf accumulation
2Object-generated harmful factors
If the tool surface is made rough with many protrusions, then swarf restraint and contact resistance are reduced, but the contact area with workpiece decreases
Solution Approach 1:
Rather than making the entire surface rough with protrusions, only partial areas are modified. The recesses are strategically placed to provide the necessary reduction in contact resistance while leaving sufficient surface area for effective cutting contact
3Reliability
If complex surface structures with multiple recess types are created, then cutting performance and tool lifetime are improved, but manufacturing complexity increases
Solution Approach 1:
The complex surface structure is segmented into two distinct recess types (first recesses between protrusions and second recesses inside or between protrusions) with different functions. This segmentation allows each recess type to be optimized for its specific purpose while maintaining overall manufacturing feasibility
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration improves tool lifetime by reducing swarf restraint and contact resistance, allowing for more accurate and efficient processing of workpieces with reduced wear and increased cutting performance.
Implementation Method 1
formed using laser irradiation to enhance contact and reduce wear
Data Source
AI summary
A tool of the present disclosure includes a tip end portion. The tip end portion has a surface. At least a part of the surface includes a plurality of protrusions, a first recess provided by contact between ends of two adjacent protrusions of the protrusions, and a second recess different from the first recess. The second recess is provided inside at least one of the protrusions or provided to extend across the two adjacent protrusions.