Milling Tool Recess Geometry for Chip Flow and Self-Cooling
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Solution Overview
Problem
Milling tools face challenges in efficiently machining various metallic materials without interrupting the process, as they often experience heat buildup and chip removal issues, especially when operating without cooling lubricants, leading to reduced tool life and increased wear.
Innovation Solution
Incorporating a recess on the cutting face and the back of the cutting edge, which maintains a specific radial distance from the cutting edge to promote chip flow and cooling, regardless of the use of cooling lubricants, and featuring cavities that enhance turbulence and surface area for improved cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a milling tool operates without cooling lubricants to reduce operational complexity, then ease of operation is improved, but heat buildup and tool wear increase reducing tool life
Solution Approach 1:
The chip groove with recesses is designed to automatically generate air cushions and air vortices during operation, creating a self-cooling and self-lubricating effect without requiring external cooling lubricants. The tool serves its own cooling and lubrication needs through its geometric design
Solution Approach 2:
Air is utilized as a cooling and lubricating medium through the formation of air cushions and air vortices in the recesses of the chip groove. This pneumatic approach replaces traditional liquid cooling lubricants, reducing operational complexity while maintaining tool life
2Duration of action of stationary object
If cooling lubricants are used to reduce heat buildup and wear, then tool life is improved, but operational complexity and cost increase
Solution Approach 1:
The geometric design of the chip groove with strategically positioned recesses enables the tool to automatically generate cooling and lubricating air cushions during operation, eliminating the need for external cooling lubricant systems and reducing operational complexity
Solution Approach 2:
The invention extracts and eliminates the need for cooling lubricants by incorporating self-cooling features directly into the tool geometry. The harmful dependency on external lubricants is removed while maintaining the beneficial cooling and lubrication effects
3Temperature
If the recess is positioned closer to the cutting edge to enhance cooling effect, then cooling effectiveness is improved, but chip flow and shearing process are adversely influenced
Solution Approach 1:
The chip groove is designed with varying local characteristics: the recesses are positioned at specific distances from the cutting edge to provide localized cooling where needed, while maintaining an open groove geometry in the chip flow path to ensure smooth chip evacuation. Each region of the chip groove has optimized properties for its specific function
Solution Approach 2:
The recesses are positioned to provide sufficient cooling effect without over-cooling that would interfere with chip flow. The partial cooling action in the recesses is balanced with the open groove design to maintain overall productivity
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 recess and cavity design facilitate trouble-free, low-wear operation across different materials like aluminum, HSS steel, and titanium, allowing for continuous use without tool changes by reducing friction, heat buildup, and enhancing coolant effectiveness.
Implementation Method 1
When the milling tool is operated without coolant, air cushions or air vortices form in the recess. These air cushions and vortices facilitate chip flow by reducing chip friction
Implementation Method 2
These air cushions and vortices facilitate chip flow by reducing chip friction and thus heat generation
Implementation Method 3
The turbulent air also more readily absorbs heat from the milling tool, cooling it more effectively
Implementation Method 4
The turbulent air also more readily absorbs heat from the milling tool, cooling it more effectively
Implementation Method 5
operating the milling tool according to the invention using a cooling lubricant leads to its accumulation in the recess, where it promotes the flow of chips on the one hand and serves to cool the heat-stressed milling tool on the other
Implementation Method 6
featuring cavities that enhance turbulence and surface area for improved cooling
Data Source
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AI summary
A milling tool with at least one peripheral cutting edge (1) and with a recess (24) extending between the rake face (8) and the groove base (9) substantially parallel to the cutting edge (6) and at a radial distance (A) from the cutting edge (6) of at least 13 to 20% of the diameter of the milling tool. The invention further relates to such a milling tool with a cutting edge back (5) adjoining the cutting edge (6) opposite to the direction of rotation (D) and with a circumferential clearance surface (11) of the cutting edge back (5) adjoining the cutting edge (6), characterized by a recess (26) on the cutting edge back (5) extending substantially parallel to the cutting edge (6) and adjoining the clearance surface (11).