Multi-Bevel Step Drill Chip Window Design
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Solution Overview
Problem
Conventional multi-chamfer step tools face chip jamming issues, particularly in cutting steps with small machining diameters due to limited chip flute volume, leading to inefficient chip removal.
Innovation Solution
A rotary-driven multi-chamfer step tool with staggered cutting stages, where each cutting stage has multiple cutting edges and corresponding flutes, and adjacent flutes are connected via a chip window that breaks through the web between them, allowing for improved chip evacuation by increasing the volume available for chip removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of stationary object
If the axial length of a cutting step with a small machining diameter is increased, then the chip flute volume is increased, but the risk of chip jamming increases
Solution Approach 1:
The invention introduces a radial dimension solution by breaking through the web between adjacent flutes to create chip windows. Instead of only increasing axial length, chips are redirected radially through the web into adjacent flutes, providing an additional evacuation pathway that solves the volume limitation without compromising reliability
Solution Approach 2:
The continuous chip flute is segmented by introducing chip windows that break through the web. This segmentation creates multiple independent chip evacuation zones, allowing chips to be redirected from one flute to another through the chip window, thereby improving chip removal reliability in small diameter cutting steps
2Volume of stationary object
If the radial depth of chip flutes is increased, then the chip flute volume is increased, but the core diameter is reduced
Solution Approach 1:
The invention shifts from increasing radial depth to utilizing the circumferential dimension by creating chip windows between adjacent flutes. Chips are evacuated radially through the web into adjacent flutes, allowing sufficient chip volume without increasing the radial depth of individual flutes, thus preserving core diameter
3Device complexity
If common chip flutes are used for multiple cutting stages, then the device complexity is reduced, but the chip removal efficiency deteriorates
Solution Approach 1:
While maintaining a common chip flute structure for multiple cutting stages, the invention segments the chip evacuation path by introducing chip windows between adjacent flutes. This allows chips from different cutting stages to be redirected into different evacuation zones, improving chip removal efficiency without requiring separate flutes for each stage
Solution Approach 2:
The chip window acts as an intermediary structure that connects adjacent flutes through the web. It enables efficient chip transfer between flutes while maintaining the simplicity of a common chip flute configuration, thus improving productivity without significantly increasing device complexity
Data Source
Figure 1a~1b
Figure 2a~2b
Figure 3a~3b
AI summary
The invention relates to a rotationally driven multi-bevel step tool, particularly a step drill for drilling into solid material, comprising a plurality of one-edged or multi-edged cutting steps which are arranged in a staggered manner in the cutting and advancing directions and each have a number of flutes that corresponds to the number of edges. Flutes (23, 33) adjoining each other in the circumferential direction are separated from each other by a web (24). According to the invention, the flues (23, 33) adjoining each other in the circumferential direction of two consecutive cutting steps (20, 30) in the cutting and advancing directions are connected to each other by a metal-cutting window (25) that is open on the circumferential side and interrupts the interposed web (24).