Rotating Tool Asymmetric Cutting Edge Angles Vibration
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Solution Overview
Problem
Existing rotating tools face challenges in effectively preventing chattering vibrations due to self-excited vibrations during cutting, particularly because the phase differences of regenerative vibrations between cutting edges are uniform, leading to inadequate vibration suppression when multiple chip discharge grooves are used.
Innovation Solution
The rotating tool features a unique configuration with at least four chip discharge grooves, where the cutting inserts are arranged with varying angles around the axial line, including a maximum, minimum, and multiple intermediate angles, creating distinct phase differences between cutting edges to reduce self-excited vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If cutting edges are disposed at equal pitch in circumferential direction, then manufacturing simplicity is improved, but self-excited vibrations easily occur due to same phase differences
Solution Approach 1:
The patent applies asymmetry by disposing cutting edges at unequal circumferential pitches, specifically with different angle relationships (first angle different from second angle) between adjacent cutting edges. This asymmetric arrangement creates different phase differences for regenerative vibrations, preventing synchronous vibration and effectively suppressing self-excited vibrations during machining.
2Device complexity
If only two kinds of inclination patterns are provided, then device complexity is reduced, but vibration suppression effect is insufficient when three or more chip discharge grooves exist
Solution Approach 1:
The patent applies local quality by providing different inclination patterns for different chip discharge grooves. Specifically, when three or more chip discharge grooves are present, at least three different inclination patterns are provided, with each groove having a distinct pattern. This ensures that cutting edges in different grooves generate vibrations with different phases, achieving effective vibration suppression across all grooves.
3Productivity
If multiple cutting inserts are arranged in multiple stages along chip discharge groove, then productivity is improved, but chattering vibrations occur due to self-excited vibrations
Solution Approach 1:
The patent combines asymmetric arrangement of cutting edges at different stages along the chip discharge groove with unequal circumferential pitches. This dual asymmetric configuration ensures that cutting edges at multiple stages generate regenerative vibrations with different phases, preventing the buildup of self-excited vibrations while maintaining high productivity through multiple cutting inserts.
Data Source
AI summary
A rotating tool includes a tool body which rotates around an axial line, four or more chip discharge grooves which are formed on an outer periphery of the tool body with gaps therebetween in a circumferential direction, and a plurality of cutting inserts which are arranged in multiple stages along the chip discharge grooves. In a cross-sectional view perpendicular to the axial line, when a center angle formed between a pair of virtual straight lines which connects each of the cutting edges of the cutting inserts disposed in a pair of chip discharge grooves adjacent to each other in the circumferential direction and the axial line to each other is defined as an angle, a plurality of angles formed around the axial line include one maximum angle (θmax), one minimum angle (θmin), and two or more angles other than the angle (θmax) and the angle (θmin).