Milling Tool Chip Pocket Grooves for Smoother Chip Evacuation
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Solution Overview
Problem
Existing milling tools face issues with chip jamming due to friction in the chip evacuation process, leading to tool breakage and poor surface quality, as chips rub against continuous ridges in the chip pocket.
Innovation Solution
A tool body with a surface pattern of intersecting first and second grooves, formed using ball-nose milling cutters, reduces friction and improves coolant distribution, minimizing the risk of chip jamming and enhancing machining efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If smooth grooves separated by continuous ridges are formed in the chip pocket wall surface, then chip evacuation path is provided, but chips rub continuously against the ridges causing increased friction and slowed chip flow
Solution Approach 1:
The continuous ridges are segmented into discrete sections by transverse grooves that intersect the longitudinal grooves. This segmentation breaks the continuous contact surface into discrete segments, allowing chips to pass over rather than rub continuously against the ridge surfaces, thereby reducing friction while maintaining the chip evacuation path structure
Solution Approach 2:
Transverse grooves are added in a second dimension perpendicular to the longitudinal grooves, creating an intersecting groove pattern. This dimensional addition transforms the simple linear groove structure into a two-dimensional network, enabling chips to follow alternative paths and reducing continuous contact with ridges
2Temperature
If coolant/lubricant is applied during wet machining, then cooling and lubrication is provided, but distribution of coolant/lubricant over the wall surface needs improvement for optimal chip flow
Solution Approach 1:
The wall surface is given non-uniform local properties through the groove pattern, where grooves create localized channels that actively guide and distribute coolant/lubricant flow. Different regions of the wall surface have different functions: grooves serve as coolant channels while ridges provide structural support and chip guidance, creating locally optimized conditions for both cooling and chip evacuation
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The surface pattern reduces friction during chip evacuation, minimizes the risk of chip jamming, and improves coolant distribution, leading to smoother chip flow and reduced tool wear, thus enhancing machining efficiency and surface quality.
Implementation Method 1
Thanks to the grooves, a reduced contact area is achieved between a chip being evacuated via the chip pocket during milling and the front wall surface of the chip pocket. The friction, and consequently also the risk of chip jamming, are thereby reduced and the chip flows smoothly over the surface pattern.
Implementation Method 2
Furthermore, since the first and second grooves intersect, during wet machining when coolant/lubricant is applied to the tool and the cutting area via an external arrangement or via internal coolant channels arranged in the tool body, the distribution of coolant/lubricant over the wall surface is improved, such that the chips flow smoothly over the surface pattern.
Data Source
AI summary
A tool body for a milling tool includes a front end and a rear end between which a center axis and a peripheral envelope surface extend. The tool body is arranged to be rotated in a direction of rotation around the center axis. At least one insert seat is configured to support a cutting insert. A chip pocket is provided in front of the insert seat in the direction of rotation, delimited by a wall surface. A surface pattern including a plurality of first grooves and second grooves is formed on at least a portion of the wall surface. The second grooves intersect the first grooves and each groove of the first grooves and/or each groove of the second grooves has a concave groove profile.