Radius End Mill Corner Edge Curvature for Load Stability
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Solution Overview
Problem
Existing radius end mills experience damage to corner cutting edges due to abrupt changes in cutting edge strength and load variations, leading to potential surface roughness issues from torn chips.
Innovation Solution
A radius end mill design where the corner cutting edge forms a convex arc shape, with the intersection point between the corner and end cutting edges located closer to the radial inner peripheral side, reducing abrupt rake angle changes and load variations, and minimizing chip generation across the intersection line.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a stepped portion or intersection ridgeline is formed at the rake face to divide chips, then chip processability is improved, but the rake angle changes abruptly causing corner cutting edge damage and surface roughness degradation
Solution Approach 1:
The patent applies curvature by forming a convex arc-shaped intersection line between the end cutting edge rake face and corner cutting edge rake face, replacing the conventional straight or stepped intersection ridgeline. This curved geometry eliminates abrupt rake angle changes, distributes cutting loads uniformly along the corner cutting edge, and prevents edge damage while maintaining effective chip division capabilities
2Productivity
If the intersection ridgeline intersects the corner cutting edge at the middle portion, then chip division is enhanced, but cutting load variations increase and corner cutting edge damage occurs
Solution Approach 1:
The patent applies local quality by positioning the intersection line to extend from the rear end side of the corner cutting edge protruding end toward the radial inner peripheral side, placing the tip closer to the radial inner peripheral side than the center of the convex arc. This localized geometric configuration optimizes chip division at the intersection region while maintaining uniform load distribution along the corner cutting edge, preventing both over-concentration and under-utilization of cutting forces
Data Source
Figure 1
Figure 2
AI summary
Damage to a corner cutting edge or degradation of the roughness of a surface of workpiece caused by changes in the cutting edge strength of the corner cutting edge or variations of cutting load is prevented. A flute (4) is formed at the outer periphery of a tip portion of an end mill body (1) rotated around an axis (O), the tip outer peripheral side of the wall face of the flute which faces a rotational direction (T) is used as a corner cutting edge rake face (11), a corner cutting edge (12) forming a convex arc shape of which the rotation locus becomes convex toward the tip outer peripheral side is formed at a side ridge portion of the corner cutting edge rake face, a gash (7) is formed on the inner peripheral side of the corner cutting edge rake face (11), the wall face of the gash which faces the rotational direction (T) is used as an end cutting edge rake face (8), an end cutting edge (9) connected to the corner cutting edge (12) and extending toward the inner peripheral side is formed at a tip-side side ridge portion of the end cutting edge rake face, and an intersection line (L) between the corner cutting edge rake face (11) and the end cutting edge rake face (8) is located closer to the radial inner peripheral side with respect to the axis (O) than the center (S) of the convex arc that the corner cutting edge (12) forms in the rotation locus, and extends from the rear end side in the direction of the axis (O) more than a protruding end (P) of the corner cutting edge (12) in the direction of the axis (O).