Micro Form End Mill With Radial Offset Edges for Surface Accuracy

Solution Overview

Problem

The need for micro end mills with improved dimensional accuracy and surface roughness in manufacturing components in the micron range, particularly for fuel cell components, is not adequately met by scaling down larger end mills, as machining conditions and geometry requirements differ significantly.

Innovation Solution

A micro form end mill with a cutting head having radially offset cutting edges and S-shaped segments, allowing for adjustable engagement conditions and optimized cutting edge geometry to achieve uniform dimensional accuracy and surface quality, featuring polycrystalline diamond cutting edges and multiple cutting teeth for enhanced precision and tool life.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Length of moving object

If conventional end mill geometry is simply scaled down from larger end mills, then tool diameter is reduced to micron range, but dimensional accuracy and surface roughness deteriorate due to different machining conditions

Engineering Contradiction:

Improvetool diameterVSAvoiddimensional accuracy

Core Design Contradiction:

Length of moving objectVSManufacturing precision

Solution Approach 1:

The patent applies local quality by giving different radial positions to different cutting edges. Specifically, at least two cutting edges are arranged with a radial offset from each other, meaning they are positioned at different radial distances from the longitudinal axis. This creates localized variations in cutting conditions across different edges, allowing optimal engagement with the workpiece at multiple radial positions simultaneously, thereby maintaining high dimensional accuracy in micron-range tools.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent changes the geometric parameters of the cutting edges by introducing radial offset. Instead of all cutting edges being at the same radial position (conventional design), the invention varies the radial position parameter of different cutting edges. This parameter change allows the tool to maintain effective cutting engagement and dimensional accuracy even at reduced tool diameters in the micron range.

Inventive Principle:

Principle #35Parameter changes

2Length of moving object

If conventional end mill geometry is simply scaled down from larger end mills, then tool diameter is reduced to micron range, but surface roughness deteriorates

Engineering Contradiction:

Improvetool diameterVSAvoidsurface roughness

Core Design Contradiction:

Length of moving objectVSObject-affected harmful factors

Solution Approach 1:

The patent applies local quality by giving different radial positions to different cutting edges. Specifically, at least two cutting edges are arranged with a radial offset from each other, meaning they are positioned at different radial distances from the longitudinal axis. This creates localized variations in cutting conditions across different edges, allowing optimal engagement with the workpiece at multiple radial positions simultaneously, thereby maintaining high dimensional accuracy in micron-range tools.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent changes the geometric parameters of the cutting edges by introducing radial offset. Instead of all cutting edges being at the same radial position (conventional design), the invention varies the radial position parameter of different cutting edges. This parameter change allows the tool to maintain effective cutting engagement and dimensional accuracy even at reduced tool diameters in the micron range.

Inventive Principle:

Principle #35Parameter changes

3Device complexity

If all cutting edges are positioned at the same radial distance from the longitudinal axis, then tool geometry is simple, but chatter marks occur and surface quality deteriorates

Engineering Contradiction:

Improvecutting edge arrangementVSAvoidchatter marks

Core Design Contradiction:

Device complexityVSObject-affected harmful factors

Solution Approach 1:

The patent applies local quality by giving different radial positions to different cutting edges. Specifically, at least two cutting edges are arranged with a radial offset from each other, meaning they are positioned at different radial distances from the longitudinal axis. This creates localized variations in cutting conditions across different edges, allowing optimal engagement with the workpiece at multiple radial positions simultaneously, thereby maintaining high dimensional accuracy in micron-range tools.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS20240051043A1Micro form end mill

Publication Date: 2024.02.15 ZECHA HARTMETALL WERKZEUGFABATION

AI summary

A micro form end mill includes a tool shank (2) and a cutting head (3) fixedly connected to the tool shank (2). The cutting head (3) has a plurality of cutting teeth (Z), and each of the plurality of cutting teeth (Z) has a cutting edge (S). A maximum radial distance (Amax) of cutting points (6, 7, 8, 9) on the cutting edge (S) from the longitudinal axis (L) is less than 0.5 mm. At least two of the cutting edges (S) are arranged with a radial offset (V) from one another at least regionally. The radial offset (V) corresponds to a difference in the radial distances from the longitudinal axis (L) of such cutting points (6, 7, 8, 9) to the at least two cutting edges (S) that lie in a common plane (E) that is perpendicular to the longitudinal axis (L).