Rotary End-Mill Dimple Patterning for Flat Low-Friction Surfaces
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Solution Overview
Problem
Existing dimple processing methods, such as laser irradiation and shot peening, face issues like thermal stress, dross formation, bulging, and residual stress, which can lead to deformation or breakage, and fail to uniformly reduce frictional resistance and collect abrasion powders effectively.
Innovation Solution
A dimple processing method using a rotary cutting tool with cutting edge portions arranged on a rod-shaped main body, where the tool is rotated and moved in a feed direction orthogonal to its axis, and also in an axial direction, creating dimples that are spaced and partially overlapping, ensuring consistent dimple distribution to capture abrasion powders and reduce frictional resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If laser irradiation method is used to form dimples, then dimples can be formed on the workpiece surface, but thermal stress causes dross to adhere to the workpiece and becomes difficult to remove
Solution Approach 1:
The patent replaces the thermal field (laser irradiation) with a mechanical field (rotary cutting tool) to form dimples. The cutting tool mechanically removes material to create dimples without generating thermal stress, thereby eliminating dross adhesion while maintaining effective dimple formation for reducing frictional resistance.
2Manufacturing precision
If shot peening method is used to form dimples, then dimples can be formed by microbead collision, but bulges are formed around the dimples causing the workpiece to become non-flat
Solution Approach 1:
The patent replaces the impact-based mechanical system (shot peening) with a controlled cutting system (rotary cutting tool). The cutting tool precisely removes material to form dimples with controlled depth and shape, preventing the formation of bulges around the dimples and maintaining workpiece flatness.
3Ease of manufacture
If conventional rotary cutting tool method is used with cutting edges slightly contacting the surface, then a polka-dot pattern can be formed, but the dimples are not uniformly distributed and do not effectively reduce frictional resistance
Solution Approach 1:
The patent applies local quality by varying the depth of dimples in different regions. The cutting tool is moved in the axial direction to create dimples with different depths, optimizing the distribution and effectiveness of dimples for reducing frictional resistance while maintaining uniform coverage.
Solution Approach 2:
The patent adds the axial dimension to the conventional two-dimensional dimple formation. By moving the cutting tool in the axial direction in addition to the feed direction, the patent creates a three-dimensional dimple distribution pattern that enhances frictional resistance reduction effectiveness.
4Reliability
If dimples are formed to reduce frictional resistance, then abrasion powders can be caught in the dimples, but the dimples must be uniformly distributed to effectively capture powders and reduce friction
Solution Approach 1:
The patent ensures continuous and uniform dimple formation by maintaining continuous contact between the cutting edges and the workpiece surface during rotation and feed movement. This continuous action creates uniformly distributed dimples along the entire processing path, ensuring effective abrasion powder capture and frictional resistance reduction throughout the contact area.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method effectively reduces frictional resistance and improves wear resistance by ensuring consistent dimple distribution and capture of abrasion powders, preventing bulging and residual stress, while maintaining a flat surface and reducing the risk of deformation.
Implementation Method 1
a plurality of cutting edge portions 5 which are arranged side by side on a lead edge line 10 having a lead angle 8 with respect to a line 7 parallel to the axis 6
Data Source
AI summary
An end mill having a plurality of cutting edges on a surface of a rod-shaped main body is rotated about its longitudinal axis and is moved relative to a workpiece in a feed direction tangential and orthogonal to the longitudinal axis along the workpiece. The end mill is also moved relative to the workpiece in a reciprocal manner in the axial direction while it is moved in the feed direction. In this way, a plurality of dimples are formed by the end mill on the workpiece, such that the dimples are relatively spaced apart from each other on the workpiece. The plurality of dimples are arranged side by side in the feed direction along a line inclined at a predetermined angle relative to the feed direction so as to be offset while partially overlapping with respect to each other in the axial direction.