Milling Tool Finishing Edge Design for Chatter and Burr Control
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Solution Overview
Problem
High-performance machining processes face limitations due to material removal rate instability caused by self-excited vibrations (chatter) and burr formation, which hampers achieving high surface qualities and productivity in milling tools, especially when using tools with flank chamfers.
Innovation Solution
A milling tool design featuring a finishing cutting edge with a greater distance from the axis of rotation than the roughing cutting edge, and an unchamfered or minimally chamfered finishing land, reduces burr formation and chatter by minimizing lateral material displacement and increasing the passive force on the roughing cutting edge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a flank chamfer is provided on the roughing cutting edge, then stability against chattering is improved, but burr formation increases and surface quality deteriorates
Solution Approach 1:
The cutting edge is segmented into two distinct parts: a roughing cutting edge with a chamfer for stable material removal, and a finishing cutting edge without chamfer for high-quality surface finish. This segmentation allows each part to optimize its function independently, resolving the contradiction between chatter stability and surface quality
Solution Approach 2:
Different local qualities are applied to different parts of the cutting tool. The roughing cutting edge has a chamfered flank face for stability, while the finishing cutting edge has an unchamfered or minimally chamfered flank face for burr-free finishing. This local differentiation resolves the contradiction by providing appropriate characteristics in each location
2Productivity
If high material removal rates are pursued through high-performance cutting, then productivity increases, but self-excited vibrations (chatter) occur causing process instability
Solution Approach 1:
The cutting process is segmented into roughing and finishing phases with dedicated cutting edges for each. The roughing cutting edge with chamfer handles high material removal rates, while the finishing cutting edge ensures process stability and quality, allowing high productivity without sacrificing stability
Solution Approach 2:
The roughing cutting edge performs preliminary material removal with its chamfered design that promotes stability. This preliminary action prepares the workpiece for the finishing cutting edge, enabling high material removal rates while maintaining process stability through the staged approach
3Reliability
If a support chamfer with large support land width is used, then chatter resistance is improved, but lateral material displacement increases causing burr formation
Solution Approach 1:
The tool design segments the chamfer function to only the roughing cutting edge. The finishing cutting edge has no chamfer or minimal chamfer, eliminating the source of burr formation while the roughing cutting edge maintains chatter resistance through its chamfered design
Solution Approach 2:
The chamfer characteristic is applied locally only where needed for stability (roughing cutting edge), while the finishing cutting edge has a different local quality (no chamfer) to prevent burrs. This resolves the contradiction by applying chamfer characteristics selectively
Data Source
Figure 1~4
AI summary
The invention relates to a milling tool (10) with an axis of rotation (D) around which the milling machine (10) rotates during operation, at least one roughing blade (16) which has a roughing blade edge (20), a flank face (24) and a supporting bevel (26) between the roughing blade edge (20) and the flank face (24), wherein the supporting bevel (26) has a supporting bevel width (bf) and wherein the roughing blade edge (20) has a roughing blade edge distance from the axis of rotation (D), and at least one finishing blade (18) which has a finishing blade edge (22), wherein the finishing blade edge (22) has a finishing blade edge distance from the axis of rotation (D) which is larger that the roughing blade edge distance; according to the invention the finishing blade edge (22) is unbeveled or has a finishing bevel with a finishing bevel width that is at most one-third of the supporting bevel width (bf).