Solid End Mill Geometry for Positive Rake and Chip Evacuation
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Solution Overview
Problem
The manufacturing and cutting performance of existing solid end mills with straight and non-inclined peripheral cutting edges are inadequate due to difficulties in achieving a suitable radial rake angle, leading to poor tool life and chip evacuation during the milling of dovetail slots in turbine engine components.
Innovation Solution
A solid end mill with peripheral cutting edges that extend at a linear and constant axial inclination angle between 5° and 15°, allowing for the grinding of positive radial rake angles along the entire cutting edge, which reduces strain on the neck portion and improves cutting performance and tool life by facilitating better chip evacuation and reducing vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If straight and non-inclined peripheral cutting edges are used, then manufacturing is simplified, but cutting performance and tool life deteriorate
Solution Approach 1:
The patent applies parameter changes by introducing a specific axial inclination angle range (5°-15°) for the peripheral cutting edges. This parameter modification resolves the contradiction by enabling both manufacturability through controlled geometry and improved tool life through optimized cutting mechanics, eliminating the need for complex curved profiles while achieving superior performance
2Ease of manufacture
If straight and non-inclined peripheral cutting edges are used, then manufacturing is simplified, but chip evacuation deteriorates
Solution Approach 1:
The patent modifies the geometric parameter of the cutting edges by applying a constant axial inclination angle of 5°-15°. This change simultaneously simplifies manufacturing compared to curved profiles and dramatically improves chip evacuation by creating effective chip channels, thus resolving the contradiction between ease of manufacture and productivity
3Shape
If large difference in diameter between lobe and neck cutting edge portions is used, then dovetail slot profile is achieved, but radial rake angle manufacturing deteriorates
Solution Approach 1:
The patent resolves this contradiction by changing the geometric parameter approach - instead of relying on large diameter variations, it applies a controlled axial inclination angle (5°-15°) that enables consistent positive radial rake angles across all cutting edge portions while maintaining the required dovetail slot profile geometry
4Productivity
If axial inclination angle is increased, then chip evacuation and cutting performance improve, but manufacturing complexity increases
Solution Approach 1:
The patent optimizes the axial inclination angle parameter within a specific range (5°-15°) that delivers significant improvements in chip evacuation and cutting performance while avoiding the manufacturing complexity of higher angles. This parameter optimization resolves the contradiction by finding the optimal balance point where performance gains are maximized without excessive complexity
Data Source
AI summary
A solid end mill is rotatable around a central rotational axis and includes a cutting portion having a plurality flutes with peripheral cutting edges formed between associated rake surfaces and clearance surfaces. The peripheral cutting edge forms a convexly curved lobe cutting edge portion disposed along an axial front part of the cutting portion. A neck cutting edge portion is connected to the lobe cutting edge portion and is disposed along an axial intermediate part of the cutting portion. A shoulder cutting edge portion is connected to the neck cutting edge portion and is disposed along an axial rear part of the cutting portion. The peripheral cutting edge extends at a linear and constant axial inclination angle θ within the range 5°≤θ≤15°. The rake surface forms positive radial rake angles αL,N,S along the entire extension of the peripheral cutting edge.