Face Milling Tool Geometry for Vibration Reduction
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Solution Overview
Problem
Conventional face milling tools experience issues with cutting behavior, chip formation, evacuation, toughness, vibrations, and noise levels, particularly at acute entering angles, which affect machining efficiency and tool longevity.
Innovation Solution
The face milling tool is designed with specific geometric configurations, including an axial tipping-in angle between -20° and 0°, a radial tipping-in angle between -60° and -25°, and an angle of inclination between 15° and 50°, along with a double-sided cutting insert with a negative basic shape and multiple cutting edges, to enhance cutting behavior, chip evacuation, and tool durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a conventional face milling tool with acute entering angle is used, then chip formation and evacuation are problematic, but cutting behavior and machining smoothness deteriorate with vibrations and noise
Solution Approach 1:
The patent applies parameter changes by optimizing the angle of inclination λ to be between 15° and 50°, which fundamentally alters the cutting geometry. This parameter modification enables the cutting insert to enter the workpiece gradually from the lower end to the upper end, transforming the cutting process to reduce vibrations and noise while maintaining effective chip formation and evacuation
2Reliability
If the angle of inclination is increased to improve toughness behavior, then machining smoothness improves, but device complexity increases due to specific geometric configurations
Solution Approach 1:
The patent applies local quality by creating specific geometric features at critical locations: the upper extension plane is positioned at a radial tipping-in angle γf between -60° and -25°, and the axial tipping-in angle γm is set between -20° and 0°. These localized geometric modifications at the cutting insert interface provide improved toughness behavior and machining smoothness without requiring complex overall tool design
3Reliability
If radial tipping-in angle is made more negative to achieve large angle of inclination, then toughness and machining smoothness improve, but insert seat accessibility for production and maintenance becomes more difficult
Solution Approach 1:
The patent applies asymmetry by positioning the upper extension plane at a specific radial tipping-in angle γf between -60° and -25°, creating an asymmetric geometry relative to the tool axis. This asymmetric configuration achieves the desired large angle of inclination for improved toughness while the specific range selection balances manufacturing accessibility, allowing insert seats to remain accessible for production and maintenance operations
4Duration of action of moving object
If cutting insert service life is extended through geometric optimization, then tool economy improves, but device complexity increases due to multiple angle specifications
Solution Approach 1:
The patent applies parameter changes by establishing specific ranges for three critical angles: angle of inclination λ (15°-50°), radial tipping-in angle γf (-60° to -25°), and axial tipping-in angle γm (-20° to 0°). These coordinated parameter modifications extend cutting insert service life by improving cutting edge toughness and reducing vibrations, while the defined ranges provide practical guidance for manufacturing without excessive complexity
Data Source
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AI summary
A face milling tool (101) comprising a tool body (102) including a central rotation axis (C1) around which the tool is rotatable, and at least one insert seat formed in a transition between a front end (104) and an envelope surface (106) of the tool. The tool further comprises at least one cutting insert (1) mounted in the insert seat, the cutting insert comprising an upper side defining an upper extension plane, a cutting edge extending around the circumference of the upper side, and a lower side defining a lower extension plane directed towards the bottom support surface of the insert seat. A centre axis extends perpendicularly through the upper and the lower extension planes. The tool is configured such that a main cutting edge portion is at an entering angle κ smaller than 80° and such that the upper extension plane is at a radial tipping-in angle -60° ≤ γf ≤ -25° and at an axial tipping-in angle -20° ≤ γm ≤ 0°, such that an angle of inclination λ of the main cutting edge portion is within the range 15° ≤ λ ≤ 50°.