Radius Endmill Curved Bottom Edge Reduces Cutting Resistance
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Solution Overview
Problem
Conventional radius endmills face challenges with high cutting resistance, reduced durability, and thick, heavy chips that can cause tool breakage and surface defects, particularly when performing deep milling operations, which often require cutting fluids and increase environmental impact.
Innovation Solution
The radius endmill features spiral-shaped peripheral cutting edges, bottom cutting edges with convex circular arc-shaped ridge lines, and rounded corner cutting edges with increased ridge line lengths, dispersing load and reducing cutting resistance, allowing for thinner, lighter chips and improved tool durability without the need for cutting fluids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the required depth of cut and overhang length of cutting tool are increased, then the cutting operation capability is improved, but tool rigidity decreases causing chattering and reduced machining efficiency
Solution Approach 1:
The patent applies curvature to the ridge lines of bottom cutting edges, changing them from straight lines to convex circular arc shapes. This curvature design modifies the cutting edge geometry to reduce chattering and improve tool performance during deep milling operations with increased overhang length, directly addressing the rigidity issue without sacrificing cutting capability
2Reliability
If the number of revolutions of cutting tool is reduced to avoid chattering, then tool stability is improved, but feed rate decreases reducing machining efficiency
Solution Approach 1:
The convex circular arc-shaped ridge lines of bottom cutting edges create a negative radial rake angle that reduces chattering, allowing the tool to maintain stability at lower revolutions while still enabling higher feed rates, thus resolving the trade-off between stability and productivity
3Ease of manufacture
If conventional straight ridge line design is used for bottom cutting edges, then manufacturing is simple, but cutting resistance is high causing thick chips and potential tool breakage
Solution Approach 1:
The patent replaces straight ridge lines with convex circular arc-shaped ridge lines for bottom cutting edges. This curvature creates a negative radial rake angle that reduces cutting resistance and produces thinner, lighter chips that are easier to evacuate, eliminating the risk of tool breakage and surface defects while remaining manufacturable
4Productivity
If cutting fluid is used to evacuate thick chips, then chip evacuation is improved, but environmental impact increases and machining cost increases
Solution Approach 1:
The convex circular arc-shaped ridge lines create negative radial rake that produces thinner, lighter chips with better flow characteristics. These chips can be evacuated smoothly without cutting fluid, eliminating environmental concerns and additional machining costs while maintaining high productivity
Data Source
AI summary
A radius endmill has a peripheral cutting edge, a bottom cutting edge, and a rounded corner cutting edges whose ridge line is defined by a circular arc having a given radius as measured in a side view of the endmill that is parallel to the axis. The rounded corner cutting edge is located in a corner portion of the endmill in which the outer peripheral and the axial end intersect each other such that the peripheral cutting edge and the bottom cutting edge are connected to each other through the rounded corner cutting edge. The bottom cutting edge has a radially inner end lying at the axis, and a radially outer end at which the bottom cutting edge is connected to the rounded corner cutting edge. The bottom cutting edge is curved such that its ridge line is defined by a circular arc as seen in a plan view of the endmill that is perpendicular to the axis.