Solid Milling Tool Flank Chamfer for Low-Vibration Deep Machining
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Solution Overview
Problem
Full milling tools face challenges in achieving precision and long service life due to vibrations and uneven material removal during machining, particularly at large machining depths with long tools, which affects dimensional accuracy.
Innovation Solution
A full milling tool design featuring a flank chamfer with a decreasing width from the front to the rear of the working area, extending over both main and secondary cutting edges, providing improved cutting pressure distribution and reduced vibrations, while maintaining sufficient support for low-vibration operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a constant width flank chamfer is used on the open surface, then the tool provides sufficient support for stable machining, but vibrations occur and dimensional accuracy deteriorates, especially at large machining depths
Solution Approach 1:
The patent applies local quality by varying the flank chamfer width along the axial direction of the tool. The chamfer width is smaller in the front cutting area (near the tool tip) and larger in the rear cutting area (near the tool shank). This localized variation allows the front cutting edges to engage the workpiece with minimal support interference, reducing vibrations and improving dimensional accuracy, while the rear cutting edges benefit from increased support stability.
2Manufacturing precision
If the flank chamfer width is reduced to minimize vibrations, then dimensional accuracy improves, but tool support stability deteriorates
Solution Approach 1:
The patent implements a dynamic approach by making the flank chamfer width variable rather than constant. The gradual transition from smaller width at the front to larger width at the rear creates a dynamic support system that adapts to the different requirements of front and rear cutting edges, maintaining overall tool stability while allowing reduced vibrations in the critical front cutting zone.
3Reliability
If a larger flank chamfer is used to increase tool support, then tool stability improves, but vibrations increase and dimensional accuracy worsens
Solution Approach 1:
By applying local quality, the patent restricts the larger chamfer width to only the rear cutting area where support stability is needed, while keeping the chamfer width smaller in the front cutting area to minimize vibrations. This localized differentiation eliminates excessive vibrations in the critical cutting zone while preserving tool support stability in the rear section.
Data Source
Figure 1a~2
Figure 3~4
AI summary
A solid milling tool (10) for rotary material machining has an elongated tool shank with a working area (13) in which cutting edges (17.1, 17.2, 17.3) with associated rake faces (20) and clearance faces (22) arranged behind the cutting edges (17.1, 17.2, 17.3) with respect to one direction of rotation are provided. Each of the cutting edges (17.1, 17.2, 17.3) comprises a main cutting edge area on the side of the shank and a secondary cutting edge area on the end face, wherein a clearance chamfer (30) is formed on the associated clearance face (22) of at least one cutting edge (17.1, 17.2, 17.3) in the main cutting edge area. In the main cutting area, the width (bStf1, bStf2) of the free surface chamfer (30) decreases from a front sub-area to a rear sub-area adjacent to a rear end of the working area (13).The solid milling tool (10) enables the machining of delicate components or component sections with small wall thicknesses while adhering to the specified dimensional tolerances at high speeds and feed rates.