Milling Tool Recessed Cutting Edge Chip Removal
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Solution Overview
Problem
Conventional milling tools face challenges in efficiently removing chips during the formation of grooves, particularly in 'fir tree' shaped grooves, which can lead to cutter jamming, often requiring complex machining to address this issue.
Innovation Solution
A milling tool design featuring a combination of recessed and non-recessed cutting edges, where at least one cutting edge is recessed starting from a non-zero distance and the others are non-recessed, extending to the tool end, with recessed edges eliminating teeth to facilitate chip removal and improve manufacturing simplicity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If portions of cutting edges are removed to facilitate chip removal, then chip removal efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The cutting edges are segmented into two distinct types: recessed cutting edges (where portions are removed) and non-recessed cutting edges (where full portions are retained). This segmentation allows different zones of the same tool to perform different functions - recessed edges facilitate chip removal while non-recessed edges maintain cutting effectiveness, resolving the contradiction between chip removal efficiency and manufacturing complexity
Solution Approach 2:
Different portions of the cutting edges have different geometries tailored to their specific functions. The recessed portions are designed with specific removal patterns to create chip escape pathways, while the non-recessed portions maintain full cutting geometry. This local differentiation optimizes each zone for its specific task while maintaining overall tool functionality
2Productivity
If recessed cutting edges are used to create space for chip exit, then chip removal is improved, but tool structure complexity increases
Solution Approach 1:
Instead of removing portions from all cutting edges (excessive action), the invention applies recessing only to selected cutting edges (partial action). This partial application is sufficient to create the necessary chip escape pathways while avoiding the unnecessary complexity that would result from modifying every cutting edge, thus resolving the contradiction between chip removal effectiveness and tool structure complexity
Data Source
AI summary
A milling tool includes a tool body having a longitudinal axis and a first end. A plurality of flutes are provided in the tool body and extend to the first end of the tool body. A plurality of cutting edges are provided. Each cutting edge is associated with a respective one of the plurality of flutes, each cutting edge being substantially identical to each other one of the plurality of cutting edges except that at least one but not all of the cutting edges is a recessed cutting edge and at least one but not all of the cutting edges is a non-recessed cutting edge. Each recessed cutting edge begins at a non-zero distance from the first end of the tool body and each non-recessed cutting edge extends to the first end of the tool body.