Solid Carbide End Mill Drilling Geometry
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Solution Overview
Problem
Conventional end milling cutters are not suitable for drilling due to instability and durability issues with secondary cutting edges, and geometry limitations that hinder chip removal and axial chip ejection during drilling operations.
Innovation Solution
A solid carbide end milling cutter with a single, flat or continuously curved end face on at least one cutting edge, featuring a clearance angle for stability and heat dissipation, along with thinning of the core between cutting edges and a concave shape for enhanced chip guidance, allowing for improved stability and performance during drilling and milling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional end milling cutters are used for drilling, then the tool can perform both peripheral and face milling, but the secondary cutting edges lack stability and durability
Solution Approach 1:
The patent applies different geometric characteristics to different parts of the cutting edges. The secondary cutting edges are given a specific end face geometry with clearance angles between 5° and 7° and a single flat or continuously curved surface, while the main cutting edges maintain their traditional geometry. This localized optimization ensures that each cutting edge type has the ideal geometry for its specific function, resolving the contradiction between versatility and reliability.
2Reliability
If the end face geometry is optimized for drilling, then drilling performance improves, but milling performance may be compromised
Solution Approach 1:
The patent designs the end mill with a universal geometry that performs optimally in both drilling and milling operations. The cutting edges are configured with a single flat or continuously curved end face that provides stable chip formation and heat dissipation during drilling, while the helical arrangement and clearance angles ensure smooth running and excellent milling performance. This universal design resolves the contradiction between specialized drilling optimization and general milling capability.
3Device complexity
If multiple free surfaces with different free angles are used on cutting edges, then geometric flexibility increases, but stability and heat dissipation decrease
Solution Approach 1:
The patent applies a uniform geometric characteristic—a single flat or continuously curved end face—to all secondary cutting edges. This homogeneous geometry provides consistent clearance angles and uniform heat dissipation paths across all cutting edges, eliminating the instability that would result from multiple different free surfaces. The homogeneity ensures predictable performance and reliable heat management during operation.
4Productivity
If chip flutes are designed for conventional milling, then milling operations are efficient, but chip spaces clog quickly during drilling
Solution Approach 1:
The patent employs helical cutting edges with optimized helix angles that create dynamic chip flow patterns suitable for both milling and drilling. The continuous curved end face geometry works in conjunction with the helical structure to guide chips axially during drilling, preventing clogging while maintaining the efficient chip evacuation characteristics needed for milling operations. This dynamic design adapts the chip flow behavior to the specific operation being performed.
Data Source
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AI summary
The invention relates to an end mill 1, preferably made of solid carbide, with a mounting section 2 and a cutting area 3, wherein the cutting area 3 is formed by a core 8 and three, four, or five cutting edges 4, 5, 6, 7 arranged helically around a rotational axis 9 of the end mill 1, each of which has a circumferential main cutting edge 10 and a secondary cutting edge 11 on an end face 12 of the cutting area 3. In order to create an end mill that is easy to manufacture and optimized for drilling, at least one cutting edge 4, 5, 6, 7 on the end face 12 of the cutting area 3 has a single, flat or continuously curved end surface 15, which limits the cutting edge 4, 5, 6, 7 in the longitudinal direction of the end mill 1 on the end face 12.