Blended Gash Corner Radius End Mill Discontinuity

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Solution Overview

Problem

Corner radius end mills with blended gashes face discontinuity issues at the intersection of the cutting edge and flute rake surface, leading to inefficiencies in machining, particularly in reducing power consumption and minimizing vibrations.

Innovation Solution

A corner radius end mill design featuring a helical flute with a specific helix angle and a blended gash that extends from the second half-sector, blending the end gash surface and flute rake surface, with the second extremity positioned to reduce discontinuity, and employing high positive rake angles to enhance machining efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a blended gash is added to prevent discontinuities, then surface finish quality improves, but device complexity increases

Engineering Contradiction:

Improvesurface finish qualityVSAvoidgash structure complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The blended gash is segmented into two distinct portions: a first portion extending from the end gash surface to the cutting edge, and a second portion extending from the cutting edge to the flute rake surface. This segmentation allows each portion to be optimized independently for its specific function while maintaining overall simplicity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different portions of the blended gash are assigned different functions: the first portion primarily addresses surface finish quality by blending the end gash surface, while the second portion addresses discontinuity prevention at the flute rake surface. This local differentiation resolves the contradiction by providing targeted solutions without unnecessary complexity

Inventive Principle:

Principle #3Local quality

2Reliability

If the blended gash extends further along the cutting edge, then discontinuity prevention improves, but power consumption increases

Engineering Contradiction:

Improvediscontinuity preventionVSAvoidpower consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The blended gash extends partially along the cutting edge rather than covering the entire length. The first portion addresses the critical end gash surface area, and the second portion extends just enough to prevent discontinuities at the flute rake surface, avoiding excessive material removal that would increase power consumption

Inventive Principle:

Principle #16Partial or excessive action

3Manufacturing precision

If the blended gash extends into the first half-sector, then end gash surface blending improves, but discontinuity at the cutting edge increases

Engineering Contradiction:

Improveend gash surface blendingVSAvoidcutting edge continuity

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The blended gash is positioned asymmetrically with respect to the corner sector, extending primarily into the second half-sector rather than symmetrically into both half-sectors. This asymmetric positioning allows effective end gash surface blending while avoiding creation of discontinuities at the cutting edge in the first half-sector

Inventive Principle:

Principle #4Asymmetry

Data Source

PatentEP2919934B1Corner radius end mill

Publication Date: 2017.11.01 ISCAR LTD

Figure 1
Figure 2A~2C
Figure 3A~3C

AI summary

A comer radius end mill (10) includes a blended gash (40) extending along a cutting edge (44). The blended gash (40) is formed in a corner sector of the end mill. The blended gash (40) extends from a first extremity such that it leaves more than half of the radius corner cutting edge (44) of radius (R) free of gashing. The blended gash (40) blends an end gash surface (66) and flute rake surface (48) of the comer radius end mill (10).