Solid Milling Tool Transition Surface for Large Plunge Angles
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Solution Overview
Problem
Conventional milling tools have limitations in achieving large plunge angles and extended service life, especially when machining difficult materials, which restricts their applicability in precision and fine machining operations.
Innovation Solution
A full milling tool design featuring a transition surface between secondary cutting edges, which enhances chip removal and tool stability, allowing for larger plunge angles and extended service life, and is produced through specific grinding processes to optimize the geometry for improved performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional milling tool geometry is used, then the tool can be manufactured with standard processes, but the plunge angle is limited and service life is reduced
Solution Approach 1:
The tool geometry is segmented into distinct functional zones: the working area with helical main cutting edges, the end face with secondary cutting edges, and the transition surface connecting them. This segmentation allows each zone to be optimized independently for its specific function while maintaining manufacturability through standardized grinding processes.
Solution Approach 2:
The invention adds a transition surface that connects the end face secondary cutting edges to the shell-side flutes, creating a new geometric dimension. This transition surface enables chips to be guided from the end face through the flutes, allowing larger plunge angles without compromising chip removal or tool stability.
2Productivity
If larger plunge angles are achieved, then tool performance in angular and helical plunging improves, but chip removal becomes more difficult
Solution Approach 1:
The transition surface acts as an intermediary element between the end face secondary cutting edges and the shell-side flutes. It provides a smooth geometric transition that guides chips from the end face cutting zone into the flutes, facilitating chip removal even at large plunge angles where conventional geometries would cause chip clogging.
3Manufacturing precision
If the tool is designed for precision machining, then manufacturing accuracy improves, but the tool size must be above a certain minimum
Solution Approach 1:
The tool design integrates multiple cutting functions into a single solid tool body. The helical main cutting edges on the shell side provide radial cutting capability, while the secondary cutting edges on the end face provide axial cutting capability. This multi-functionality allows the tool to perform both radial and axial machining operations, eliminating the need for separate tools and enabling precision machining at small diameters down to 1 mm.
Data Source
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AI summary
A solid milling tool (100) for rotary material machining comprises an elongated tool shank which has a working area in which at least two helical main cutting edges (117.1, 117.2, 117.3, 117.4) with associated main rake faces (122) and rake flutes (121) extending forward in the direction of rotation are arranged on the outer surface. The at least two helical main cutting edges (117.1...4) continue into an end face of the tool shank and form at least two secondary cutting edges (132) with associated secondary rake faces (136), wherein a face gap (141.2) is recessed between each secondary rake face (136) and a clearance face of the secondary cutting edge (132) preceding it in the direction of rotation. Between each pair of successive secondary cutting edges (132) in the direction of rotation, a transition surface (151.2) is formed, which at least adjoins the secondary cladding surface (136) of the secondary cutting edge (117.2) following in the direction of rotation, the end gap (141.2) and the clamping groove (121) is adjacent. This geometry allows for large immersion angles while maintaining a long service life.