Rotary Tool Flank Face Geometry for Surface Finish and Edge Durability
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Solution Overview
Problem
Existing rotary tools for milling metal workpieces face challenges in achieving optimal surface roughness and durability of cutting edges due to uneven clearance angles and excessive cutting loads, which affect machining efficiency and product quality.
Innovation Solution
A rotary tool design featuring a cylindrical body with specific flank face configurations, including a chisel edge, long and short cutting edges, and distinct flank faces with varying clearance angles and widths, which reduces excessive cutting loads and enhances burnishing effects to improve surface roughness and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a uniform clearance angle is applied to all flank faces, then the manufacturing process is simplified, but the cutting load distribution becomes uneven and surface roughness deteriorates
Solution Approach 1:
The patent applies different clearance angles to different flank faces: the first flank face has a clearance angle of 5-15 degrees while the second flank face has a clearance angle of 0-5 degrees. This local differentiation allows the first flank face to provide adequate clearance for cutting edge durability, while the second flank face with smaller clearance angle provides burnishing effect for improved surface roughness (Ra 0.4μm or less).
Solution Approach 2:
The end mill is segmented into distinct functional zones: a long flank face with larger clearance angle for primary cutting and edge protection, and a short flank face with smaller clearance angle for burnishing. This segmentation allows each zone to perform its specific function optimally without compromising the other.
2Productivity
If excessive cutting load is applied to achieve high productivity, then machining speed increases, but durability of cutting edges deteriorates
Solution Approach 1:
The first flank face is designed with a larger clearance angle (5-15 degrees) specifically to reduce cutting load and improve durability of the cutting edges during high-speed machining, while maintaining productivity through optimized load distribution.
3Device complexity
If a single flank face configuration is used, then the device complexity is reduced, but the burnishing effect is insufficient for achieving desired surface roughness
Solution Approach 1:
The end mill incorporates two distinct flank faces: a long flank face for cutting and a short flank face for burnishing. The short flank face with smaller clearance angle (0-5 degrees) and width of 0.5-2mm provides the necessary burnishing effect to achieve surface roughness of Ra 0.4μm or less, while the long flank face handles the primary cutting function.
Solution Approach 2:
Different regions of the end mill are assigned different clearance angles: the long flank face has 5-15 degrees for cutting, while the short flank face has 0-5 degrees for burnishing. This local quality differentiation enables the burnishing function without significantly complicating the overall device structure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The tool achieves improved surface roughness and extended durability of cutting edges by distributing cutting loads effectively, ensuring high machining accuracy and product quality.
Implementation Method 1
Bringing the round surface into contact with a workpiece during machining of the workpiece allows a burnishing effect to be exhibited by the round surface, in other words, the flank face and a surface roughness of a machined surface to be improved
Data Source
AI summary
The short flank face includes a second flank face that is adjacent to the short cutting edge rearward of a rotation axis in a rotation direction and is flat and a third flank face that is adjacent to the second flank face rearward of the rotation axis in the rotation direction and is flat. In front view of the body from the front end, a maximum value of a width of the second flank face in the direction orthogonal to the short cutting edge is smaller than a maximum value of a width of the long flank face in the direction orthogonal to the long cutting edge, and a clearance angle of the second flank face is smaller than a clearance angle of the long flank face.