Solid End Mill Complex Clearance Surface Vibration Damping
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Solution Overview
Problem
Solid end mills with cutting diameters larger than 12 mm experience significant vibrations (chatter) when cutting metals, and existing solutions like 'micro land' are inefficient in suppressing vibrations across various materials and require high spindle power, making them difficult to use for high-temperature alloys.
Innovation Solution
A solid end mill design featuring a complex clearance surface with projections adjacent the cutting edge, extending the entire width and length of the clearance surface, which reduces vibrations by incorporating a sinusoidal wave pattern of varying primary clearance angles along the blade.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional straight or eccentric clearance surfaces are used in solid end mills with cutting diameter ≥12mm, then the tool structure is simple and easy to manufacture, but significant vibrations (chatter) occur during metal cutting
Solution Approach 1:
The patent applies curvature by implementing a sinusoidal wave pattern on the clearance surface instead of straight or eccentric lines. The clearance surface features a continuous curved geometry defined by the sinusoidal function, creating varying clearance angles that dampen vibrations while maintaining manufacturability through specialized grinding processes.
Solution Approach 2:
The sinusoidal wave pattern creates periodic variations in the clearance angle along the clearance surface. This periodic geometry modulates the interaction between the tool and workpiece, creating a rhythmic variation in cutting conditions that suppresses chatter vibrations through controlled periodic action.
2Object-affected harmful factors
If 'micro land' clearance facet is ground adjacent the cutting edge to suppress vibrations, then vibration suppression improves, but high accuracy grinding is required with minimum 2-3 passes per tooth and spindle power consumption increases considerably
Solution Approach 1:
The clearance surface is segmented into multiple zones with varying clearance angles through the sinusoidal wave pattern. Instead of a single uniform micro land facet, the clearance surface is divided into numerous small segments along its length, each with different local clearance angles that collectively suppress vibrations across various materials.
Solution Approach 2:
Different portions of the clearance surface have different local clearance angles created by the sinusoidal pattern. The clearance angle varies locally along the clearance surface, providing optimized local conditions for different cutting depths and materials, thereby reducing vibrations without requiring high-precision uniform grinding across the entire surface.
3Object-affected harmful factors
If 'micro land' clearance facet is implemented to reduce vibrations, then vibration suppression is achieved, but specific energy consumption increases and heat generation increases, making it difficult to cut high temperature alloys
Solution Approach 1:
The patent changes the clearance angle parameter dynamically along the clearance surface using a sinusoidal variation. Instead of a fixed clearance angle, the angle varies continuously according to the sinusoidal function, optimizing the energy efficiency and heat generation characteristics for different cutting conditions and materials including high-temperature alloys.
Data Source
AI summary
In one aspect, rotary cutting tools are described comprising clearances with projections adjacent the cutting edge and extending the width and length of the clearance surface of each tooth. This design can assist in reducing vibration or chatter during cutting operations.