Spiral Flute Tool Anti-Phase Edge Design
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Solution Overview
Problem
Existing tools with wave-shaped or interrupted cutting edges fail to effectively reduce the maximum value of cutting resistance when adjacent peripheral edges cut a workpiece simultaneously, as they do not specify the relationship between waveforms of adjacent edges at contact points, leading to insufficient shortening of cutting edge length and increased resistance.
Innovation Solution
The tool's design sets the lead, waveform pitch, and number of edges to satisfy specific relational expressions, ensuring adjacent peripheral edges are in an anti-phase relationship when cutting, thereby shortening the cutting edge length and reducing maximum cutting resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If wave-shaped roughing formed cutting edges or interrupted cutting edges are adopted to shorten the length of cutting edges that contact the workpiece, then cutting resistance is reduced, but the maximum value of cutting resistance is not sufficiently reduced when adjacent peripheral edges cut the workpiece simultaneously
Solution Approach 1:
The patent applies parameter changes by precisely controlling the phase shift between adjacent peripheral edges to be exactly P/2 (half the waveform pitch). This specific parameter setting ensures that when multiple cutting edges contact the workpiece simultaneously, their waveforms are in anti-phase, creating complementary contact patterns that consistently reduce the maximum length of cutting edges in contact, thereby reliably reducing maximum cutting resistance by 6.5% to 9.3%.
2Device complexity
If phase shifts between adjacent peripheral edges are set to a constant value (one pitch per round), then the relationship between cutting edges is simplified, but chattering vibration is generated and tool life is not extended
Solution Approach 1:
The patent changes the phase shift parameter from the conventional constant value (P/N, where N is the number of edges) to a specific value of P/2 (half the waveform pitch). This parameter change eliminates chattering vibration by ensuring that adjacent cutting edges are in anti-phase when contacting the workpiece simultaneously, while still maintaining a regular and simple phase shift relationship that is easy to implement in manufacturing.
3Object-generated harmful factors
If waveform pitches are increased or decreased at a predetermined cycle to prevent chattering vibration, then vibration is reduced, but the relationship between waveforms of adjacent peripheral edges at simultaneous contact positions is not optimized
Solution Approach 1:
Instead of changing waveform pitches at predetermined cycles, the patent applies a constant phase shift of P/2 to all adjacent peripheral edges. This approach simultaneously prevents chattering vibration and optimizes the cutting resistance reduction effect, as the anti-phase relationship between adjacent edges ensures consistent shortening of the cutting edge contact length regardless of the axial position.
Solution Approach 2:
The patent utilizes the periodic nature of the wave-shaped cutting edges combined with a fixed phase shift of P/2. This creates a periodic anti-phase relationship between adjacent peripheral edges as they rotate, which consistently reduces cutting resistance while preventing chattering vibration, without requiring variable pitch adjustments.
4Ease of manufacture
If the length of cutting edges that contact the workpiece simultaneously is determined randomly, then the cutting process is simple, but the effect of reducing maximum cutting resistance is insufficient
Solution Approach 1:
The patent applies a specific parameter setting of phase shift equal to P/2 (half the waveform pitch) between adjacent peripheral edges. This precise parameter control ensures that when multiple cutting edges contact the workpiece simultaneously, their waveforms are in anti-phase, which systematically reduces the maximum length of cutting edges in contact. This maintains manufacturing simplicity while achieving consistent 6.5% to 9.3% reduction in maximum cutting resistance.
Data Source
AI summary
To provide a tool that can reduce the maximum value of cutting resistance when adjacent peripheral edges cut a workpiece simultaneously. A lead L of a spiral flute 21, a waveform pitch P, the number of edges N of peripheral edges 22, and a natural number m are set to satisfy L/N=m×P−P/N±P/2 or L/N=m×P+P/N±P/2, the waveforms of adjacent ones of the peripheral edges 22 at the positions where they contact a workpiece simultaneously are in an anti-phase relationship when the adjacent peripheral edges 22 cut the workpiece simultaneously. Therefore, there is an effect that the length of the cutting edges that contact the workpiece simultaneously is shortened to reduce the maximum value of cutting resistance.