Segmented Milling Burr Reduces Vibration and Chip Injury
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Solution Overview
Problem
Conventional milling burrs for handheld machines suffer from poor manual controllability, high operator exposure to vibrations, and increased risk of injury due to chip formation during steel cutting operations.
Innovation Solution
A milling burr design featuring a cutting member made of hard metal with facets on cutting teeth, an alternating arrangement of cutting tooth portions and tooth dividers, and specific angular configurations to minimize chip adherence and reduce vibration exposure, where only every second cutting tooth engages with the workpiece per revolution, resulting in larger chips and reduced operator risk.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If conventional milling burr design is used, then the structure is simple and easy to manufacture, but the operator is exposed to high vibrations and increased risk of injury from chip formation
Solution Approach 1:
The cutting member is segmented into multiple cutting teeth (at least 12) arranged around the periphery, with each cutting tooth further divided into cutting tooth portions by tooth dividers. This segmentation distributes the cutting load across multiple elements, reducing vibrations and controlling chip formation to minimize injury risk while maintaining structural feasibility
Solution Approach 2:
The cutting member is made of hard metal material, which provides the necessary hardness and wear resistance for cutting steel materials while maintaining structural integrity. This composite approach combines the hardness of hard metal with the geometric design of alternating cutting tooth portions and tooth dividers to achieve both cutting performance and vibration reduction
2Object-affected harmful factors
If more cutting teeth are added to reduce vibrations, then the number of cutting teeth increases, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
Each cutting tooth is segmented into cutting tooth portions by tooth dividers, creating an alternating pattern that allows for effective vibration reduction with a manageable number of teeth. The segmentation is achieved through forming tooth dividers in the cutting teeth, which is a feasible manufacturing process that does not require excessive complexity
Solution Approach 2:
The design specifies particular parameters including at least 12 cutting teeth, tooth dividers with specific length b, cutting tooth portions with length a, and angular spacing of 30° to 60° between adjacent cutting teeth. These parameter specifications provide clear manufacturing guidelines that balance vibration reduction with manufacturing ease
3Object-affected harmful factors
If facets are added to cutting teeth to control chip formation, then the risk of injury from chips is reduced, but the manufacturing complexity increases
Solution Approach 1:
Facets are added locally to specific surfaces of the cutting teeth, particularly to the cutting tooth portions, rather than redesigning the entire cutting tooth geometry. This localized modification controls chip formation and reduces injury risk while minimizing the increase in manufacturing complexity, as facets can be formed through standard machining or forming processes
Data Source
AI summary
A milling burr for use in handheld machines has a shank and a cutting member of hard metal which is rigidly connected to said shank. The cutting member is provided with cutting teeth which extend in a first direction of twist. The cutting teeth are divided in cutting tooth portions by rows of tooth dividers extending in a second direction of twist. The cutting tooth portions and the tooth dividers are arranged one behind the other when seen in the peripheral direction in such a way that an overlap occurs in an in each case alternating manner when seen in the peripheral direction.