Rotary Tool Flank Kink Geometry for Stable Chip Removal
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Solution Overview
Problem
Rotary tools with large clearance angles, while providing strength, become less stable during operation due to reduced body truncation, necessitating a design that balances stability and cutting performance.
Innovation Solution
A rotary tool design featuring a flank with a kink that varies the clearance angle along its length, comprising a concave configuration with a leading and trailing partial surface, allowing for independent adjustment of clearance angles and improved stability through a convex-concave profile, and enhanced coolant supply.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the clearance angle is increased to strengthen the body of the rotary tool, then the strength is improved, but the stability during operation deteriorates
Solution Approach 1:
The flank is designed with varying clearance angles at different locations: a larger clearance angle at the leading end for effective chip removal, and a smaller clearance angle at the trailing end for enhanced stability. This local differentiation allows each region to optimize its function without compromising the other.
Solution Approach 2:
The flank is segmented into multiple regions with different clearance angles, specifically a leading partial surface and a trailing partial surface separated by a kink. This segmentation enables independent optimization of cutting performance and operational stability.
2Productivity
If the clearance angle is increased to improve cutting performance, then the chip removal efficiency is improved, but the body truncation is reduced leading to decreased stability
Solution Approach 1:
The flank is designed with varying clearance angles at different locations: a larger clearance angle at the leading end for effective chip removal, and a smaller clearance angle at the trailing end for enhanced stability. This local differentiation allows each region to optimize its function without compromising the other.
Solution Approach 2:
The clearance angle is made dynamic rather than constant, varying along the length of the flank to adapt to different functional requirements at different positions during the cutting cycle.
Data Source
AI summary
A rotary tool (2) is provided, comprising: a main blade (4), a chip flute (6), a lateral surface (8), a flank (10) trailing the main blade (4) and extending from the main blade (4) up to the lateral surface (8) and to the chip flute (6), wherein the flank (10) comprises a kink (12) and is thus concave in configuration, wherein the kink (12) extends from the lateral surface (8) up to the chip flute (6) and thus divides the flank (10) into a leading partial surface (14) and a trailing partial surface (16). The invention further relates to a method for manufacturing such a rotary tool (2).