Roughing Mill Cutter Serrated Edge Chip Jam Prevention

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Solution Overview

Problem

Existing roughing milling cutters with beveled cutting edges often experience chip jams due to abrupt chip deflection, leading to incomplete chip removal and flute clogging, despite the stabilization of the cutting edge.

Innovation Solution

The cutting edge is serrated in the longitudinal direction with alternating crests and valleys, allowing chips to be smoothly deflected and discharged into the chip groove, preventing jams while maintaining edge stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If a beveled cutting edge is used, then the cutting edge is stabilized and breakouts are avoided, but chip jams occur due to abrupt chip deflection

Engineering Contradiction:

Improvecutting edge stabilityVSAvoidchip jams

Core Design Contradiction:

Stability of the object's compositionVSObject-generated harmful factors

Solution Approach 1:

The cutting edge is segmented into multiple serrations with alternating crests and valleys along its length. This segmentation creates multiple small deflection points rather than a single abrupt deflection, allowing chips to be gradually guided into the chip groove and preventing jams while maintaining overall edge stability through the beveled geometry.

Inventive Principle:

Principle #1Segmentation

2Productivity

If chips are discharged at right angle to the cutting edge, then chip removal is achieved, but abrupt deflection causes chip jams in the chip groove

Engineering Contradiction:

Improvechip removalVSAvoidchip jams

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The serrated cutting edge creates a curved, wave-like path for chip deflection rather than a sharp angular turn. The alternating crests and valleys form a gradual S-shaped trajectory that guides chips smoothly into the chip groove, eliminating abrupt deflection points that cause jams while maintaining effective chip removal.

Inventive Principle:

Principle #14Spheroidality (Curvature)

3Stability of the object's composition

If the cutting edge is beveled over the entire height of the wavy roughing toothing, then edge stability is maximized, but chip flow is disrupted causing jams

Engineering Contradiction:

Improvecutting edge stabilityVSAvoidchip flow

Core Design Contradiction:

Stability of the object's compositionVSEase of operation

Solution Approach 1:

The cutting edge combines two different geometric features along its length: a beveled configuration for overall stability and localized serrations with alternating crests and valleys for chip guidance. This local quality variation allows the edge to simultaneously provide structural stability through the bevel while facilitating smooth chip flow through the serrated pattern.

Inventive Principle:

Principle #3Local quality

Data Source

PatentEP2078574B1Roughing mill with inclined cutting edge

Publication Date: 2011.03.09 HOFMANN & VRATNY OHG

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AI summary

The cutter (1) has a milling area (3) including a milling surface (4) that lies in a periphery of the cutter and runs in a screw thread. The milling surface includes roughing gear teeth provided with a cutting edge (6), where the teeth run in a wave-like manner in a longitudinal direction of the screw thread. A cutting edge is slanted over an entire height of the gear teeth. A slanted region (14) of the cutting edge is provided with a serration of alternative ridges and valleys in a longitudinal direction. The milling area extends towards an upper end of a cylindrical tool shaft (2).