Milling Tool Chip Flute Radius and Core Diameter Design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Milling tools face breakage due to operating loads, as conventional designs are inadequate in managing cutting forces and torsional moments, leading to insufficient resistance against mechanical stress.
Innovation Solution
The milling tool features chip flutes with a radial direction up to the core diameter, where the core diameter increases along the cutting edge section, and the flute is divided into a chip forming area with a smaller radius of curvature and a chip removal area, reducing friction and torsional moments, and is made of composite materials like cemented carbide for enhanced robustness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional chip groove design is used, then chip removal is achieved, but cutting forces and torsional moments are high leading to tool breakage
Solution Approach 1:
The invention changes the geometric parameters of the chip groove by defining specific radius of curvature relationships (R1 < R2) between different zones. This parameter optimization reduces friction between chips and groove walls, thereby reducing cutting forces and torsional moments while maintaining effective chip removal, ultimately increasing resistance to tool breakage
2Strength
If uniform core diameter is used, then manufacturing is simple, but torsional moments cannot be effectively absorbed
Solution Approach 1:
The invention applies local quality by varying the core diameter along the tool length rather than using a uniform diameter. The core diameter increases from the cutting edge toward the shank, creating zones with different mechanical properties. This localized variation enables the tool to better distribute and absorb torsional moments generated during cutting operations
3Force
If chip groove with large radius of curvature is used, then chip removal is smooth, but deformation forces are high
Solution Approach 1:
The invention optimizes the radius of curvature parameters in different chip groove zones, specifically setting R1 < R2 where R1 is the radius in the first zone and R2 is the radius in the second zone. This parameter differentiation creates an optimal balance: the first zone with smaller radius reduces deformation forces during initial chip formation, while the second zone with larger radius ensures smooth chip flow and removal
Data Source
Figure 1~2d
Figure 3~4b
Figure 5~6b
AI summary
Rotary tool (1), in particular milling tool, wherein the rotary tool (1) is designed for rotation in a direction of rotation (R) about a longitudinal axis (L), the rotary tool (1) comprising: an end face (2), a cutting section (3) and a shank section (4), a plurality of webs (8) extending spirally along the cutting section (3), chip flutes (6) running between webs (8), wherein at least one chip flute (6) is formed in a radial direction up to a core diameter (DK), which core diameter (DK) increases at least section by section along the cutting section (3) in the direction of the shank section (4), wherein the at least one chip flute (6) is subdividable into a chip forming region (61) and a chip removal region (62), which regions (61, 62) are separated from each other in a cross-section normal to the longitudinal axis (L) by a point of contact (P) of the chip flute (6) with an incircle forming the core diameter (DK),and wherein a contour of the chip forming area (61) has a smaller radius of curvature (RF) than a contour of the chip removal area (RA).