Beveling Tool Radial Blade Geometry for Chip Discharge
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Solution Overview
Problem
Existing beveling machines suffer from imperfect edge finishes and tool damage due to chattering between the work piece and cutter, leading to rapid tool wear and inefficient chip discharge.
Innovation Solution
A beveling tool with a unique design featuring a protruded post for a bearing, threaded holes for secure attachment, radial relief angles to reduce load and prevent chattering, and honed portions on cutter blades to enhance durability and precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a traditional cutter design is used in beveling machines, then the structure is simple, but the work piece and cutter come in contact causing chattering, imperfect edge finish, and tool damage
Solution Approach 1:
The cutter is segmented into multiple radial blades (typically 3-6 blades) arranged around the circumference, each blade independently contributing to the cutting action. This segmentation allows for more uniform material removal and reduces chattering by distributing the cutting load across multiple blades rather than a single continuous cutter edge.
Solution Approach 2:
The radial blades are designed with specific geometric properties including a radial relief angle (5-15 degrees) and edge angle (15-60 degrees) optimized for the local cutting conditions. The blade thickness and geometry are locally optimized to achieve both clean cutting edges and adequate structural strength, preventing both chattering and blade breakage.
2Productivity
If the cutter contacts the work piece during beveling, then cutting action is achieved, but chattering occurs resulting in imperfect edge finish and internal part damage
Solution Approach 1:
The cutter design incorporates dynamic balance considerations with blades evenly distributed around the circumference. The radial blade configuration allows for optimized engagement angles and cutting depths that maintain stable cutting forces during rotation, preventing chattering while maintaining high cutting efficiency. The blade geometry is designed to dynamically adapt to varying work piece conditions.
Solution Approach 2:
The multiple radial blades create a periodic cutting action as they sequentially engage and disengage from the work piece during rotation. This periodic engagement distributes the cutting load over time, preventing continuous contact that causes chattering while maintaining steady material removal rates for efficient production.
3Ease of manufacture
If conventional cutter design is used, then basic beveling function is provided, but chip discharge is difficult and sparks are generated
Solution Approach 1:
Chip discharge grooves are incorporated into the cutter body, extracting the chip removal function from the basic cutting blades. These grooves provide dedicated pathways for chip ejection, separating the chip discharge function from the cutting function and enabling efficient chip removal without interfering with the cutting action or generating sparks.
4Reliability
If radial relief angles are increased to prevent chattering, then gap between work piece and cutter is improved, but cutting precision may be affected
Solution Approach 1:
The radial relief angle is optimized within a specific range (5-15 degrees) to achieve the best balance between preventing chattering and maintaining cutting precision. This parameter optimization ensures sufficient gap between the work piece and cutter to eliminate chattering while preserving adequate blade engagement for precise machining. The edge angle (15-60 degrees) is simultaneously optimized to maintain sharp cutting edges.
Data Source
Figure 1
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AI summary
The present invention provides a beveling tool (100) including a body (10) with a shaft hole (5) formed through the center; a plurality of cutter blades (20) arranged at predetermined distances on the circumferential surface of the body (10), each having a radial primary relief surface (14) with a radial primary relief angle ranging from 10 to 20 degrees and a radial secondary relief surface (16) with a radial secondary relief angle ranging from 25 to 45 degrees; discharge grooves (30) formed longitudinally between the cutter blades (20) to discharge chips produced in beveling; and a shank (40) inserted in the shaft hole (5) of the body (10), in which the body (10) and the shank (40) are connected by brazing. With the beveling tool of the present invention, it is possible to smoothly discharge chips produced in beveling and to prevent damage to the cutter blades.