End Mill with Differentiated Cutting Edge Radii
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Solution Overview
Problem
End mills with large radii experience undesirable vibration during milling, leading to noise and reduced tool life, which affects the quality of processed surfaces and tool durability.
Innovation Solution
The end mill design features a pair of helical cutting teeth with specific chamfer cutting edges, end cutting edges, and rake faces, along with defined angles and radii, which reduce contact with the workpiece and break up chips effectively, thereby minimizing vibration and noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If a large radius is provided on the cutting edge to reduce wear and improve surface roughness, then the serviceable life of the cutter is increased, but undesirable vibration occurs during milling producing noise and reducing tool life
Solution Approach 1:
The patent applies different radii to different portions of the cutting edge: a first radius at the corner where peripheral and end cutting edges meet, and a second (larger) radius along the peripheral cutting edge. This local differentiation allows the corner to have reduced vibration characteristics while the peripheral edge maintains wear resistance and surface quality, thus resolving the contradiction between tool life and vibration control.
2Manufacturing precision
If a large radius is provided on the cutting edge to reduce wear, then compliant surface roughness is improved, but excessive vibration leads to poor quality of processed surfaces
Solution Approach 1:
By providing a smaller first radius at the corner region and a larger second radius on the peripheral cutting edge, the invention locally optimizes surface quality at the corner while controlling vibration through the reduced corner radius, thereby maintaining overall surface quality without excessive vibration.
3Duration of action of stationary object
If a large radius is provided on the cutting edge to reduce wear, then the service life of the tool is extended, but excessive vibration reduces the service life of the tool
Solution Approach 1:
The differentiated radius configuration provides wear resistance through the larger peripheral radius while the smaller corner radius minimizes vibration-induced stress concentrations, thereby extending overall tool service life by balancing both protective functions.
Data Source
AI summary
An end mill may include a body elongated along an axis of rotation, the body may include a shank end and a cutting end opposite the shank end, the cutting end having a cutting diameter and defining a pair of helical flutes that form a first helical cutting tooth and a second helical cutting tooth, wherein each of the first cutting tooth and the second cutting tooth includes a peripheral cutting edge, an end cutting edge, a chamfer cutting edge extending from the peripheral cutting edge to the end cutting edge, and a rake face at least partially bounded by the end cutting edge and the chamfer cutting edge.