Rotary Tool Flute Geometry for CFRP Chip Discharge and Edge Durability
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Solution Overview
Problem
Existing rotary tools for milling processes, particularly in machining workpieces with fiber components like CFRP, face challenges in maintaining cutting edge durability and achieving effective chip discharge due to limitations in flute design and helix angles.
Innovation Solution
A rotary tool design featuring a columnar shape with spirally extending first and second flutes of different helix angles, intersecting cutting edges, and enlarged flank surfaces to enhance durability and machining performance, including the option of forward- and reverse-twisted cutting edges, and a method for manufacturing machined products using these tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single flute design with uniform helix angle is used, then the tool structure is simple, but chip discharge effectiveness and cutting edge durability are insufficient when machining fiber-reinforced materials
Solution Approach 1:
The rotary tool is segmented into multiple flutes (first flute and second flute) with different helix angles. Each flute is designed with specific geometric characteristics - the first flute has a first helix angle optimized for certain chip discharge paths, while the second flute has a second helix angle for different chip discharge patterns. This segmentation allows each flute to handle specific machining conditions, improving overall reliability and cutting edge durability when machining fiber-reinforced materials.
Solution Approach 2:
Different regions of the tool are given different local qualities through varying helix angles in different flutes. The first flute and second flute have distinct helix angles tailored to their specific functions in chip discharge and cutting edge engagement. This local optimization ensures that each part of the tool performs its function effectively, enhancing cutting edge durability without requiring complete redesign of the entire tool structure.
2Productivity
If flutes with different helix angles are implemented, then chip discharge effectiveness is improved, but manufacturing complexity increases
Solution Approach 1:
The tool is divided into multiple flutes with different helix angles to optimize chip discharge efficiency. The first flute and second flute each have specifically designed helix angles that facilitate effective chip removal in different directions and under different machining conditions. This segmentation enables superior chip discharge performance compared to single-flute designs.
Solution Approach 2:
The helix angle parameter is varied across different flutes to optimize chip discharge efficiency. By changing the helix angle parameter from the first flute to the second flute, the tool achieves different chip discharge characteristics that improve overall productivity when machining fiber-reinforced materials, despite the increased manufacturing complexity.
3Manufacturing precision
If multiple flutes with different geometries are used, then machining performance on fiber-reinforced materials is enhanced, but tool design complexity increases
Solution Approach 1:
The rotary tool employs multiple flutes with different geometric configurations, including varying helix angles and flute profiles. This segmentation allows each flute to be optimized for specific machining requirements when working with fiber-reinforced materials, thereby enhancing manufacturing precision and surface finish quality.
Solution Approach 2:
Different flutes are assigned different local geometric qualities tailored to their specific functions. The first flute and second flute have distinct helix angles and cross-sectional geometries that are locally optimized for their respective roles in cutting and chip discharge, improving machining precision on composite materials.
Data Source
AI summary
A rotary tool in a non-limiting embodiment of the present disclosure has a columnar shape. A first flute has a first helix angle having a positive value. A second flute has a second helix angle having a negative value. An outer peripheral surface includes a first outer peripheral surface and a second outer peripheral surface. A second outer peripheral surface is located on a rear side in a rotation direction of a rotation axis with respect to the first outer peripheral surface. The first outer peripheral surface includes a first flank surface extending along a first cutting edge, and a second flank surface extending along a second cutting edge. The first flank surface includes a first enlarged part whose width increases as coming closer to the second flank surface.