Segmented End Mill Geometry for Low-Resistance Engraving
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Solution Overview
Problem
Existing shank end mills are inefficient in milling smaller thicknesses and limited in engraving final products, with high material consumption and lower productivity due to small chip cross-section and extended time for longer workpiece perimeters, and limited engraving possibilities.
Innovation Solution
A cutting shank end mill with an even number of teeth and a discontinuous cutting edge design, where the total cutting length of each tooth is divided into equal gaps, and cutting edges on one tooth overlap those on the following tooth, featuring a concave cutting edge for angled milling and enhanced chip separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional shank end mills with continuous cutting edges are used, then material removal is achieved, but chip cross-section is small and cutting resistance is high, reducing productivity
Solution Approach 1:
The continuous cutting edge is segmented into multiple discrete cutting edges separated by gaps. Each cutting edge has a finite length and is separated from the next by a gap, creating a discontinuous cutting edge structure. This segmentation reduces the total contact length between the tool and workpiece, thereby reducing cutting resistance and improving chip evacuation, which directly addresses the contradiction between productivity and cutting force.
2Quantity of substance
If the total cutting length is increased to handle larger workpiece perimeters, then more material can be removed, but the time required is disproportionately extended
Solution Approach 1:
Instead of uniformly distributing cutting edges along the entire circumference, the invention concentrates the cutting action in specific localized regions by providing discrete cutting edges of optimized length at strategic positions. The cutting edges are positioned to engage the workpiece material in a controlled manner, removing material efficiently without requiring excessive total cutting length, thus reducing milling time while maintaining effective material removal capability.
3Adaptability or versatility
If standard end mills are used for engraving, then basic milling is achieved, but engraving of final products with narrow areas and corners is limited
Solution Approach 1:
The invention transitions from a conventional cylindrical end mill geometry to a design where cutting edges are arranged in a discontinuous pattern around the circumference. This dimensional reconfiguration allows the cutting edges to engage and disengage from the workpiece in a controlled sequence, enabling the tool to access narrow areas and corners more effectively while maintaining stability during engraving operations on final products.
Data Source
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AI summary
A cutting shank end mill includes a clamping shank and an even number of teeth/flutes, where the total cutting length of each tooth is divided into gaps and cutting edges which are as long as the gaps, and the cutting edges on one tooth overlap the gaps on the following tooth, wherein in a plane perpendicular to the axis of the mill and passing through any point of the main part of the total cutting length, on one tooth there is one of the cutting edges and on the following tooth there is one of the gaps. The face of the milling cutter may be equipped with at least a simple concave cutting edge to allow inclined or helical plunging to the full depth of the cutting flute.