Waveform Milling Tool Bevel Design for Chipping Prevention
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Solution Overview
Problem
Milling tools used in High Performance Cutting (HPC) technology face issues with chipping of cutting edges when machining tough materials due to brittleness, leading to high wear and tear and increased production costs, with existing solutions being either costly or inefficient.
Innovation Solution
A milling tool design where the bevel extends over the entire height of the wave form profile with an obtuse wedge angle, achieved through a simple flat grinding step, reinforcing the cutting edges and reducing chipping, and featuring a rake angle of 0° to −30° for optimal material removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a cutting profile is ground to eliminate chipping of crest edges, then chipping is reduced, but the manufacturing process becomes more complex and costly
Solution Approach 1:
The invention changes the geometric parameters of the cutting edge by applying a bevel with a specific wedge angle (more obtuse than the original milling tool wedge angle) that extends over the entire height of the crests. This parameter modification reinforces the cutting edge structure, preventing chipping while maintaining a simple single-step grinding manufacturing process
Solution Approach 2:
The invention adds a bevel dimension to the cutting edge geometry, creating a multi-faceted structure that extends the protective feature over the entire crest height. This dimensional addition strengthens the cutting edge against chipping without requiring complex multi-step manufacturing processes
2Productivity
If carbide material is used to maximize material removal rate, then productivity increases, but the brittleness causes chipping of cutting edges
Solution Approach 1:
The invention modifies the geometric parameters of the carbide cutting edge by applying a bevel with an obtuse wedge angle that extends over the entire crest height. This geometric parameter change reinforces the brittle carbide material structure, distributing stresses more effectively and preventing chipping while maintaining the high material removal rate capability
3Duration of action of stationary object
If the bevel extends over the entire height of the crests with an obtuse wedge angle, then chipping is prevented and tool endurance increases, but the grinding operation requires precise control
Solution Approach 1:
The invention specifies particular parameter ranges for the bevel geometry, including the obtuse wedge angle and the extension over the entire crest height. These defined parameters, while requiring precise control, establish clear manufacturing targets that optimize tool endurance and can be achieved through controlled single-step grinding processes
Data Source
AI summary
A milling tool for roughing workpieces is provided with a plurality of cutting flanks and flutes disposed in between. The cutting flanks are provided on the cutting side with a predetermined rake angle, and the cutting edges have moreover a profile of wave form that extends over the width of the cutting flanks. The profile of wave form is provided with a bevel having a width corresponding to at least the height of the crest, and having a wedge angle that is more obtuse than the wedge angle of the milling tool. When the tool is subjected to heavy operational demands, a chipping or breaking off of the crest edges is thereby prevented, thus increasing the service life of the tool.