Radius Endmill Nose Geometry for Thin-Plate Chatter Suppression
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Solution Overview
Problem
Existing radius endmills suffer from regenerative self-excited chatter vibrations during machining of thin plate components, leading to instability and increased machining costs due to the limitations in feed speed and depth of cut, which are exacerbated by the generation of cutting forces in the plate thickness direction.
Innovation Solution
A radius endmill with a circular arc edge having an angular range of 30° or less and a nose radius between 1 mm and 1000 mm, along with specific dimensions for the circular arc edge on both the bottom and side surfaces, is designed to reduce the regeneration width and minimize chatter vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the nose radius is increased to improve feed rate and surface roughness, then machining efficiency is improved, but chatter vibrations occur more easily in thin plate workpieces
Solution Approach 1:
The patent changes the geometric parameters of the circular arc edge, specifically limiting the angular range to 30° or less and controlling the nose radius between 1 mm and 1000 mm. This parameter optimization reduces the regeneration width to half or less of conventional designs, allowing larger nose radii to be used without causing chatter vibrations, thereby improving feed rate while maintaining machining stability.
2Manufacturing precision
If the angular range of the circular arc edge is increased to improve surface finish, then surface roughness is reduced, but the regeneration width increases causing more chatter vibrations
Solution Approach 1:
The patent optimizes the angular range parameter of the circular arc edge to 30° or less, which controls the regeneration width to half or less of conventional designs. This parameter change allows the tool to achieve good surface finish while minimizing the conditions that cause regenerative chatter vibrations.
3Ease of manufacture
If conventional radius endmill designs are used, then machining of thin plate components is possible, but regenerative self-excited chatter vibrations occur leading to increased machining costs
Solution Approach 1:
The patent changes the critical parameters of the circular arc edge (angular range ≤30° and controlled nose radius) to reduce regeneration width. This allows thin plate components to be machined without regenerative chatter vibrations, enabling increased feed rates and depths of cut that reduce machining time while maintaining ease of manufacture.
Data Source
AI summary
A radius endmill suppressing chatter vibration includes a circular arc edge provided on an outer peripheral side of a distal end portion of a tool body, and a nose (R) angle (θr) that is an angular range in which the circular arc edge is formed in a vertical section including a central axis line of the tool body and which is equal to or less than 30°. The circular arc edge is formed, as a circular arc edge for a bottom surface, from a position having a tangential line in a direction that perpendicularly intersects the central axis line to a side surface in a bottom surface of the distal end portion of the tool body in a vertical section. A nose (R) height (Hr) that is a dimension of the circular arc edge in the direction of the central axis line is equal to or less than 0.75 mm.