Milling Tool Notch Geometry for Radial Stabilization
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Solution Overview
Problem
Milling tools experience radial deflection and vibrations during oblique immersion due to machining forces, which limits feed rates and tool overhang capabilities, especially when machining complex workpieces like turbine blades.
Innovation Solution
A milling tool design featuring a special notch between the plane cutting edge and secondary cutting edge, which stabilizes the tool radially by embedding the cutting edge geometry into the workpiece, allowing for smoother operation and increased feed rates, with specific angle ranges (α, β, γ) ensuring optimal stabilization and preventing tool fracture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a milling tool is used for oblique immersion and plunging, then machining capability is improved, but radial deflection and vibrations occur due to machining forces
Solution Approach 1:
The cutting edge geometry is segmented into distinct functional zones: a plane cutting edge for primary material removal, a secondary cutting edge for finishing, and a specialized notch between them. This segmentation allows each zone to perform its specific function independently, with the notch providing radial stabilization while the cutting edges perform machining operations.
Solution Approach 2:
The solution introduces a new geometric element (the notch) in the radial dimension between the plane and secondary cutting edges. This radial stabilization feature counteracts radial deflection forces without interfering with the primary cutting action, effectively adding a stabilization dimension to the cutting edge geometry.
2Adaptability or versatility
If the tool overhang is increased for machining complex components, then adaptability is improved, but vibrations and radial deflection increase
Solution Approach 1:
The cutting edge geometry is designed with local quality variations: the plane cutting edge has specific angles for aggressive material removal, the secondary cutting edge has different angles for finishing, and the notch has precisely controlled angles (α: 90°-175°, β: 3°-90°, γ: 5°-177°) optimized for radial stabilization. Each local region is optimized for its specific function.
3Productivity
If feed rate is increased for higher productivity, then production efficiency is improved, but vibrations and radial deflection worsen
Solution Approach 1:
The notch geometry is designed in advance with specific angle ranges (α: 90°-175°, β: 3°-90°, γ: 5°-177°) to pre-establish radial stabilization. This preliminary geometric configuration ensures that when high feed rates are applied, the radial forces are automatically counteracted by the notch engagement, preventing vibrations before they can develop.
Data Source
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AI summary
The invention relates to a milling tool having a rotation axis D, consisting of a tool shank -1- and a cutting region -2-. The cutting region -2- has at least one wiper cutting edge -3- which runs approximately perpendicularly to the rotation axis D and which merges at the circumference into a main cutting edge -4- and at the centre into a secondary cutting edge -5-. The secondary cutting edge -5- is offset rearwards from the wiper cutting edge -3- in the direction of the rotation axis D. According to the invention, a notch -6- designed as a cutting edge section is formed in the transition zone between wiper cutting edge -3- and secondary cutting edge -5-. The point -7- of this notch -6-, said point -7- being the rearmost point as seen in front view in the direction of the rotation axis D, lies behind the foremost point -8- of the secondary cutting edge -5-, wherein the angle a between the wiper cutting edge -3- and the adjoining section of the notch -6- is within the range of 90° to 175° and the angle ß between the wiper cutting edge -3- and that section of the notch -6- which adjoins the secondary cutting edge -5- is within the range of 3° to 90°. The angle Y between that section of the notch -6- which adjoins the secondary cutting edge -5- and the secondary cutting edge -5- is within the range of 90° - 177°.