End Mill Dimple Processing for High-Density Surface Texturing
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Solution Overview
Problem
Existing methods for forming dimples on workpieces, such as aluminum and cast iron, face challenges in achieving high density and desired arrangements, especially on irregular surfaces and deep holes, due to issues like thermal stresses, knife marks, and limitations in forming complex configurations.
Innovation Solution
A dimples processing method using an end mill with one or two toothed elements on a rod-shaped body, capable of forming one or two dimples per rotation, allowing for high-density dimple formation on arbitrary surfaces, including irregular curved faces and deep holes, by adjusting the inclination angle and using a conical portion to secure strength and precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If laser irradiation is used to form dimples, then dimples can be formed on workpiece surfaces, but large thermal stresses arise in the workpiece due to high temperature heating
Solution Approach 1:
The patent replaces thermal processing (laser irradiation) with mechanical processing (rotating cutting tool) to form dimples. The end mill with specific toothed element configuration mechanically cuts dimples without generating thermal stress, thus substituting a mechanical system for a thermal system while achieving the same functional outcome of dimple formation.
Solution Approach 2:
The patent changes the processing parameters by using a rotating cutting tool with controlled rotational speed and feed rate instead of high-temperature laser irradiation. This parameter change from thermal to mechanical domain eliminates thermal stress while maintaining dimple formation capability through controlled mechanical cutting forces.
2Ease of manufacture
If overall cutting work is used to form dimples, then dimples can be formed on workpiece surfaces, but it is difficult to cut or machine out a uniform or even face
Solution Approach 1:
The patent segments the cutting tool into multiple discrete toothed elements (one or two cutting edges) spaced around the rod-shaped body. This segmentation allows each tooth to create individual dimples at precise intervals, producing a uniform pattern of separated dimples rather than a continuous cut, thereby achieving both dimple formation and surface uniformity.
Solution Approach 2:
The patent employs periodic action through the rotating cutting tool where toothed elements repeatedly engage and disengage from the workpiece surface during rotation. This periodic engagement creates uniformly spaced dimples at regular intervals, ensuring consistent surface uniformity while efficiently forming the desired dimple pattern through repetitive cutting cycles.
3Ease of manufacture
If shot peening is used to form dimples, then dimples can be formed on workpiece surfaces, but it is difficult to form dimples onto deep holes and concaved or dented faces
Solution Approach 1:
The patent creates a universal dimple formation tool that can process various surface geometries including flat surfaces, deep holes, and concaved or dented faces. The rotating end mill tool with its centralized toothed elements can access and form dimples on diverse surface types, making the process versatile and adaptable to different workpiece geometries unlike shot peening which is limited to accessible surfaces.
4Ease of manufacture
If decorative method with rotary cutting tool is used to form dimples, then polka-dot patterns can be formed on workpiece surfaces, but it is difficult to form dimples highly densely or onto bores deep inside cylinders and not-smooth or uneven curved faces
Solution Approach 1:
The patent applies local quality by concentrating one or two cutting edges at specific locations on the rod-shaped body, allowing precise control over dimple formation at targeted areas. This localized cutting approach enables high-density dimple formation and can adapt to complex geometries including deep bores and curved surfaces, overcoming the limitations of conventional rotary cutting tools that rely on peripheral cutting edges.
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
Enables the reduction of sliding friction and fluid resistance, improvement of wear resistance and heat-radiating properties, allowing for versatile applications like engine cylinders and artificial joints with precise dimple arrangements.
Implementation Method 1
processing dimples, which are separated away from each other, by rotary cutting a surface of a workpiece using an end mill provided with one toothed element which comprises one or two cutting edges
Data Source
AI summary
An end mill includes a major-diameter shank, a cone-shaped connector portion disposed at the end of the shank, a minor-diameter body disposed by way of the connector portion coaxially therewith, a toothed element disposed at the leading end of the body, an installation recess dented slightly in the toothed element, and a cutting edge held in the installation recess so as to swell in the shape of an arc to protrude from an outer peripheral face of the body.