End Mill Point Thinning Layout for Boring and Face Milling
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Solution Overview
Problem
Existing end mills are not suitable for boring operations due to the lack of cutting edges near the center, leading to unreliable chip removal and compromised stiffness and surface quality during face milling.
Innovation Solution
The end mill features a cutting region with at least two geometrically different point thinnings, where the first point thinning has an angle of 30° to 45° and the second point thinning has an angle of 35° to 50°, allowing for improved boring operations while maintaining face milling quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If point thinnings are provided on the end side of the cutting region to enable boring operations, then boring capability is improved, but tooth thickness and tooth stability are reduced, compromising face milling quality
Solution Approach 1:
The patent applies local quality by providing different point thinning configurations at different locations around the cutting region. Specifically, first point thinnings are provided between certain mutually adjacent cutting edges while second point thinnings are provided between other mutually adjacent cutting edges, creating localized variations in core geometry that enable boring operations in specific areas while preserving tooth thickness and stability in other areas for high-quality face milling
Solution Approach 2:
The patent segments the point thinning configuration into two distinct types: first point thinnings with specific angular dimensions and second point thinnings with different angular dimensions. This segmentation allows different regions of the end mill to serve different functions - some regions optimized for boring operations with larger point thinnings, and other regions optimized for face milling with smaller point thinnings that maintain tooth stability
2Adaptability or versatility
If cutting edges are extended close to the rotation axis to enable boring operations, then boring capability is improved, but chip removal reliability is compromised
Solution Approach 1:
The patent creates local quality variations by providing point thinnings only between specific mutually adjacent cutting edges rather than uniformly between all cutting edges. This localized approach creates adequate chip removal spaces where needed while maintaining sufficient tooth thickness and structural integrity in other regions, ensuring reliable chip removal during boring operations without compromising overall tool performance
3Adaptability or versatility
If point thinning angles are increased to improve boring operations, then boring capability is improved, but tooth thickness is reduced, compromising end mill stiffness
Solution Approach 1:
The patent implements local quality by varying point thinning angles depending on the location. First point thinnings have angular dimensions of 30° to 45° while second point thinnings have angular dimensions of 20° to 40°. This creates regions with larger point thinnings that facilitate boring operations and regions with smaller point thinnings that maintain tooth thickness and end mill stiffness
Solution Approach 2:
The patent segments the point thinning configuration into two distinct angular ranges: first point thinnings with 30° to 45° angles and second point thinnings with 20° to 40° angles. This segmentation allows the end mill to have sufficient material removal capability in specific regions while maintaining adequate structural strength and stiffness in other regions where smaller point thinnings are provided
Data Source
AI summary
An end mill, preferably formed of solid carbide, includes a fastening portion and a cutting region. The cutting region has cutting edges about a core extending helically about a rotation axis of the end mill, each cutting edge having one circumferential primary and one secondary cutting edge on an end side of the cutting region. The end side of the cutting region has first and second point thinnings of the core between mutually adjacent cutting edges. The first and second point thinnings are configured differently. The first point thinning has an angle of 30° to 45°, and the second point thinning has an angle of 35° to 50°, in terms of a normal plane to the rotation axis. The first point thinning has an opening angle of 30° to 50°, and the second point thinning has an opening angle of 40° to 60°, between flanks of the point thinning.