Three-Flute Thread Milling Cutter for Long-Chip Evacuation
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Solution Overview
Problem
Existing drill thread milling cutters struggle with machining materials that produce long chips, as the chips are difficult to transport out of the drilled hole, leading to chip lodging and damage to the milling teeth, and require increased advancing speed.
Innovation Solution
A drill thread milling cutter with a thread milling portion having three flutes and a drill tip with three lips, where each lip has a positive radial lip rake angle, enhancing chip compression and breaking, and improving chip transport and advancing speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a conventional drill thread milling cutter with two lips is used, then the drilling operation can be performed, but the chips produced are long and cannot be transported out of the drilled hole, leading to chip lodging and damage to the milling teeth
Solution Approach 1:
The patent changes the geometric parameters of the drill tip by introducing a positive radial lip rake angle (α ≥ 0°) and using three lips instead of two. This parameter change fundamentally alters the chip formation and transport mechanism, enabling long chips to be broken and evacuated effectively, thus resolving the contradiction between advancing speed and service life
Solution Approach 2:
The patent segments the chip flow path by introducing three lips that create multiple chip evacuation paths through the flutes. This segmentation allows chips to be divided and transported more efficiently out of the drilled hole, preventing chip lodging and extending tool service life while maintaining high advancing speeds
2Productivity
If the advancing speed is increased to improve productivity, then more material can be removed per unit time, but the long chips become even more difficult to transport out of the drilled hole, exacerbating chip lodging problems
Solution Approach 1:
The positive radial lip rake angle is designed to preliminarily compress and break chips at the point of formation, before they can become long and problematic. This preliminary action on chip geometry prevents the development of long chip structures that would cause lodging, enabling high advancing speeds without the harmful effects
3Device complexity
If a drill tip with two lips is used, then the structure is simpler, but the chip production and transport are insufficient for materials that produce long chips
Solution Approach 1:
By increasing from two to three lips, the patent segments the chip evacuation function into three separate paths through the flutes. This segmentation dramatically improves chip transport efficiency for materials producing long chips, while the increase in complexity from two to three lips remains manageable and justified by the significant performance improvement
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design achieves improved chip breaking and transport, extending the service life and increasing advancing speed of the drill thread milling cutter, especially when machining materials that produce long chips.
Implementation Method 1
As a result of the at least one positive radial lip rake angle, during drilling the chips are more strongly compressed in the region of the drill tip and, even in the machining of materials that produce long chips, are broken.
Data Source
AI summary
A thread milling tool extends along an axis of rotation and contains a thread milling section and a drill tip adjoining the thread milling section. The thread milling section has three cutting flutes and at least one thread milling tooth, while the drill tip has three main cutting edges, each of which reaches a main cutting circle when viewed in parallel to the axis of rotation. The main cutting circle defines a drilling diameter that can be produced by the drill tip. Each main cutting edge has a main cutting surface that is connected to one cutting flute of the cutting flutes and reaches the main cutting circle at a respective radial main cutting angle when viewed in parallel to the axis of rotation, and at least one radial main cutting angle of the radial main cutting angles is positive.