Circle Segment End Mill for 5-Axis Roughing and Wall Finishing
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Solution Overview
Problem
5-axis machining requires multiple tools, which is time-consuming and costly, necessitating a single tool capable of performing multiple functions.
Innovation Solution
A combination high feed mill circle segment cutting tool that integrates the end work of a high feed mill and the fluting of a circle segment cutter, allowing for both roughing and finishing operations in a single tool.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple tools are used in 5-axis machining, then manufacturing precision and specialized function are improved, but productivity and machining time deteriorate due to frequent tool changes
Solution Approach 1:
The patent combines two separate cutting tools (high feed mill and circle segment cutter) into a single integrated tool with a common shank. The tool features a high feed axial cutting face at the distal tip for roughing operations and a circle segment cutting portion extending from the axial cutting face for finishing operations, allowing both functions to be performed without tool changes
Solution Approach 2:
The integrated cutting tool is designed to perform multiple functions: it can execute high feed milling operations for bulk material removal and circle segment cutting operations for wall finishing, all from a single tool with a universal shank design that accommodates both cutting geometries
2Adaptability or versatility
If multiple tools are used in 5-axis machining, then operational versatility is improved, but device complexity and cost increase
Solution Approach 1:
The patent merges the functionality of two separate tools into one integrated tool body, reducing the number of tools needed in the machining system while maintaining operational versatility for both roughing and finishing operations
Solution Approach 2:
The tool design provides multi-functionality by incorporating both high feed mill and circle segment cutter capabilities in a single tool, reducing tool inventory requirements and simplifying tool management while maintaining operational flexibility
Data Source
AI summary
An end mill configured as a high feed circle segment cutter and a high feed end cutter utilizable in 5-Axis machining. The end mill comprises the end work of a high feed mill and the fluting of a circle segment cutter, thereby allowing the operator to rough out the bulk of the material with a high feed method (small axial and larger radial depths of cuts), then use the side of the tool to finish/semi-finish the walls of the part with the circle segment cutter geometry on the side of the tool.