Solid Milling Tool Asymmetrical Cutting Edges Vibration Control
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Solution Overview
Problem
Milling tools with cutting inserts have limited precision and size, making them unsuitable for precision or fine machining, and their service life is short, leading to increased costs and tool disposal, while solid milling tools face challenges with vibration and chip removal efficiency.
Innovation Solution
A full milling tool with an elongated shank and asymmetrical helical cutting edges, featuring varying core diameters and rear open surface geometries that reduce vibrations and enhance chip removal, allowing for longer tool life and reduced drive power.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If milling tools use cutting inserts to reduce costs and extend service life, then service life and cost efficiency improve, but manufacturing precision deteriorates making them unsuitable for precision or fine machining
Solution Approach 1:
The tool body is segmented into modular components including replaceable cutting inserts, allowing the cutting elements to be replaced while maintaining the precision tool body structure. This enables extended service life through insert replacement while preserving manufacturing precision through the stable, precision-machined tool body.
Solution Approach 2:
Different parts of the tool have different properties: the tool body is designed for high precision and stability, while the cutting inserts are optimized for durability and cost-effectiveness. This local differentiation allows the precision requirements to be met in the tool body while the inserts handle the wear and tear, resolving the contradiction between precision and service life.
2Duration of action of moving object
If milling tools use cutting inserts to extend service life, then service life improves, but tool size increases making them unsuitable for small diameter applications
Solution Approach 1:
The cutting inserts are designed with localized functionality, allowing them to be mounted on precision tool bodies of various diameters. This enables small diameter tools to achieve extended service life through insert replacement without compromising the compact size needed for small diameter applications.
Solution Approach 2:
The cutting inserts are designed as universal components that can be used across different tool body sizes and configurations. This universality allows the same insert design to extend service life in both small and large diameter tools, eliminating the size constraint while maintaining the service life benefit.
3Stability of the object's composition
If solid milling tools have a core diameter that increases in the axial direction to improve stability, then tool stability improves, but chip removal efficiency deteriorates
Solution Approach 1:
The flutes are segmented into multiple sections along the axial direction, with each section optimized for different functions. The lower sections have larger cross-sections for stability, while the upper sections have optimized geometries for chip removal. This segmentation allows both stability and chip removal efficiency to be maximized in their respective zones.
Solution Approach 2:
The flute geometry is optimized in multiple dimensions: the core diameter increases axially for stability, while the flute cross-sectional shape and orientation are independently optimized for chip removal. This multi-dimensional optimization allows the tool to achieve both stability through core geometry and chip removal efficiency through flute geometry without compromise.
4Object-affected harmful factors
If helical cutting edges are arranged asymmetrically to reduce vibrations, then vibration levels decrease, but manufacturing complexity increases
Solution Approach 1:
The helical cutting edges are deliberately arranged asymmetrically with different helix angles and azimuthal positions. This asymmetry creates favorable vibration characteristics by distributing cutting forces more evenly, reducing resonant vibrations. While the geometry is more complex, the benefits in vibration reduction and surface quality justify the increased manufacturing complexity.
Solution Approach 2:
The cutting edges are designed with varying parameters including different helix angles, lead angles, and azimuthal offsets. By optimizing these parameters, the tool achieves reduced vibrations and improved surface finish. The parameter variations are carefully controlled to balance vibration reduction with manufacturability, applying asymmetry where it provides the greatest benefit.
Data Source
Figure 1~4
Figure 5~6
Figure 7A~10C
AI summary
A solid milling tool (10) for rotary material machining comprises an elongated tool shank (11) which has a working area (13) in which at least three helical cutting edges (17.1, 17.2, 17.3, 17.4) with associated rake faces (18) are arranged asymmetrically. Clearance faces (22a, 22b, 22c, 22d) are located behind the cutting edges (17.1...4) with respect to one direction of rotation, and a core diameter increases axially from an end face of the solid milling tool (10) within the working area (13). At least in an end-face section of the working area (13) there is at least one front clearance surface (22a) per cutting edge (17.1...4) which is adjacent to the cutting edge (17.1...4), and a rear clearance surface (22d) which is adjacent to a rake face (18) of a subsequent cutting edge (17.1...4), wherein at least one of the cutting edges (17.1...4) The width of the rear clearance face (22d) decreases from the end face of the solid milling tool (10). The reduction in width of at least one of the rear clearance faces (22d) provides an additional degree of freedom in the machining of the chip groove (18), as the transition between the clearance face area (22a...d) and the chip groove (18) is variable and can differ from cutting edge to cutting edge (17.1...4). The geometry of the chip groove (18) can thus be further optimized for reliable chip evacuation, particularly for cutting edges (17.1...4) where the space available for machining the chip groove (18) is limited due to the interplay between asymmetry and the increase in core diameter.