END MILL HAVING TEETH AND ASSOCIATED FLUTES WITH CORRELATED PHYSICAL PARAMETERS

Abstract

An end mill includes a plurality of teeth and flutes. The teeth and their associated flutes include one or more correlated physical parameters. One such correlated parameter is that, at an axial location in a front half of an effective cutting length, at least one tooth of the plurality of teeth has a rake angle smaller than an average rake angle value of the plurality of teeth, and, at the same axial location, a flute preceding each such tooth has a helix angle larger than an average helix angle value of the plurality of flutes.

Claims

1. A finish end mill configured for rotating about a central rotation axis (A.sub.R) defining opposite axially forward and rearward directions (D.sub.F, D.sub.R), and opposite rotational preceding and succeeding directions (D.sub.P, D.sub.S), the preceding direction (D.sub.P) being the cutting direction, the end mill comprising: a shank portion; and a cutting portion extending forward from the shank portion to a cutting end face; the cutting portion comprising: an effective cutting length (L.sub.E); a diameter (D.sub.E); three or more integrally formed teeth; and flutes alternating with the three or more teeth, each flute having a helix angle and a flute depth; each tooth comprising: a rake surface; a relief surface succeeding the rake surface and having a relief surface width measurable in a plane perpendicular to the rotation axis (A.sub.R); a cutting edge formed at an intersection of the rake and relief surfaces; a relief edge spaced apart from the cutting edge and formed at an intersection of the relief surface and a flute surface of the flute succeeding the tooth; and a tooth area defined between a first radial line extending from the cutting edge to the central rotation axis and a second radial line extending from the central rotation axis to a nadir of the succeeding flute; wherein at an axial location in a front half of the effective cutting length: the flutes have an average helix angle value, with one or more flutes having a smallest helix angle value, and one or more flutes having a largest helix angle value; the flutes have a helix angle variance of 6 or less; the teeth have an average radial rake angle value, with one or more teeth having a smallest radial rake angle value, and one or more teeth having a largest radial rake angle value; at least three of the three or more teeth have different radial rake angles; and at least some of the different radial rake angle values being different from all other non-identical values by 2 or more.

2. The finish end mill according to claim 1, wherein, at an axial location in the front half of the effective cutting length: the teeth have an average tooth area value, with one or more teeth having a smallest tooth area value, and one or more teeth having a largest tooth area value; the teeth have an average relief surface width value, with one or more teeth having a smallest relief surface width value, and one or more teeth having a largest relief surface width value; and at least one tooth has a tooth area greater than the average tooth area value and a relief surface width smaller than the average relief surface width value.

3. The finish end mill according to claim 1, wherein, at an axial location in the front half of the effective cutting length: at least one tooth has a radial rake angle smaller than the average radial rake angle value; and the flute preceding each such tooth has a helix angle larger than the average helix angle value.

4. The finish end mill according to claim 3, wherein, at an axial location in a front half of an effective cutting length: each of at least two teeth has a radial rake angle smaller than the average radial rake angle value; and said flute preceding each such tooth has a helix angle larger than the average helix angle value.

5. The finish end mill according to claim 3, wherein, at an axial location in a front half of an effective cutting length: said at least one tooth has a radial rake angle smaller than the average radial rake angle value; and said flute preceding each such tooth has a helix angle equal to the largest helix angle value.

6. The finish end mill according to claim 5, wherein, at an axial location in a front half of an effective cutting length: said at least one tooth has a radial rake angle equal to the smallest radial rake angle value.

7. The finish end mill according to claim 3, wherein, at an axial location in a front half of an effective cutting length: each tooth with a radial rake angle equal to the smallest radial rake angle value is preceded by a flute with a helix angle larger than the average helix angle value.

8. The finish end mill according to claim 7, wherein, at an axial location in a front half of an effective cutting length: each tooth with a radial rake angle equal to the smallest radial rake angle value is preceded by a flute with a helix angle equal to the largest helix angle value.

9. The finish end mill according to claim 1, wherein, at an axial location in a front half of an effective cutting length: a majority of flutes have a helix angle larger than the average helix angle value, and each of said majority of flutes is succeeded by a tooth having a radial rake angle smaller than the average radial rake angle value.

10. The finish end mill according to claim 1, wherein, at an axial location in a front half of an effective cutting length: at least one tooth has a radial rake angle which is equal to the largest radial rake angle value; and the flute preceding each such tooth has a helix angle which is smaller than the largest helix angle value and larger than the smallest helix angle value.

11. The finish end mill according to claim 1, wherein at an axial location in a front half of an effective cutting length: at least one tooth has a radial rake angle greater than the average radial rake angle value; and the flute preceding each such tooth has a helix angle smaller than the average helix angle value.

12. The finish end mill according to claim 1, wherein at an axial location in the front half of the effective cutting length: successive flutes have different helix angles which vary by 3 or less.

13. The finish end mill according to claim 1, wherein at an axial location in the front half of the effective cutting length: each radial rake angle value is different from all other non-identical values in accordance with the condition: 31.

14. The finish end mill according to claim 1, wherein the effective cutting length L.sub.E is greater than 2.5D.sub.E.

15. The finish end mill according to claim 14, wherein the effective cutting length L.sub.E is less than 6D.sub.E.

16. The finish end mill according to claim 14, wherein the effective cutting length L.sub.E fulfills the condition: L.sub.E=4D.sub.E1D.sub.E.

17. The finish end mill according to claim 1, wherein, in a rearward direction from the cutting end face, index angles between each adjacent pair of cutting edges in cross-sections of the cutting portion approach equality and subsequently diverge therefrom.

18. The finish end mill according to claim 17, wherein said index angles approach equality with increasing proximity to a middle of the effective cutting length.

19. The finish end mill according to claim 1, wherein the diameter D.sub.E of the end mill has a constant value throughout the effective cutting length.

20. The finish end mill according to claim 1, wherein the three or more teeth is equal to or greater than five teeth.

21. The finish end mill according to claim 20, wherein the three or more teeth is equal to or less than 11 teeth.

22. The finish end mill according to claim 21, wherein the three or more teeth is equal to 5, 7 or 9 teeth.

23. The finish end mill according to claim 1, wherein all of said three or more teeth are smooth.

24. The finish end mill according to claim 1, wherein the flutes have a helix variance of 4 or less.

25. The finish end mill according to claim 1, wherein all helix angles are within the range of 35 to 41.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0057] For a better understanding of the subject matter of the present application, and to show how the same may be carried out in practice, reference will now be made to the accompanying drawings, in which:

[0058] FIG. 1 is a side view of an end mill according to the subject matter of the present application;

[0059] FIG. 2 is a view of a cutting end face of the end mill in FIG. 1, along a rotation axis A.sub.R, i.e. at a front end of the end mill;

[0060] FIG. 3 is a cross-section view taken along line in FIG. 1, corresponding to an axial location at a front quarter of the effective cutting length of the cutting portion;

[0061] FIG. 4 is a cross-section view taken along line IV-IV in FIG. 1, corresponding to an axial location in the middle of the effective cutting length of the cutting portion;

[0062] FIG. 5 is a cross-section view taken along line V-V in FIG. 1, corresponding to an axial location at a rear quarter of the effective cutting length of the cutting portion; and

[0063] FIG. 6 is a cross-section view taken along line VI-VI in FIG. 1, corresponding to a rear axial location, i.e. a rear end, of the effective cutting length of the cutting portion.

DETAILED DESCRIPTION

[0064] FIGS. 1 and 2 illustrate an end mill 10, typically made of extremely hard and wear-resistant material such as cemented carbide, configured for rotating about a central rotation axis A.sub.R which extends longitudinally through the center thereof.

[0065] The central rotation axis A.sub.R defines opposite axially forward and rearward directions D.sub.F, D.sub.R, and opposite rotational preceding and succeeding directions D.sub.P, D.sub.S, the preceding direction D.sub.P being the cutting direction.

[0066] The end mill 10 comprises a shank portion 12 and a cutting portion 14 extending in the forward direction D.sub.F therefrom.

[0067] The cutting portion 14 extends in the rearward direction D.sub.R from a cutting end face 16 to a furthermost flute end 18.

[0068] The cutting portion 14 is integrally formed with first, second, third, fourth, fifth, sixth and seventh teeth 20A, 20B, 20C, 20D, 20E, 20F, 20G alternated with helically shaped first, second, third, fourth, fifth, sixth and seventh flutes 22A, 22B, 22C, 22D, 22E, 22F, 22G.

[0069] To explain relative terminology used herein, for example, the first flute 22A is adjacent to the first tooth 20A in the preceding direction (D.sub.P), and could therefore be described as the flute which precedes the first tooth 20A. Another example would be that the seventh flute 22G succeeds the first tooth 20A, or, alternatively stated, that the first tooth 20A precedes the seventh flute 22G, etc.

[0070] Shown in FIG. 1, each flute 22 has a helix angle H formed with the central rotation axis A.sub.R. It is understood that the helix angles of the various flutes need not be the same, and that the helix angle of any given flute may not be constant for its entire length along the effective cutting length L.sub.E.

[0071] An effective cutting length L.sub.E of the cutting portion 14 extends from the cutting end face 16 to an axial location where tooth relief surfaces are no longer effective, which is visible in this example at the axial location designated with the reference character 29 (in this example the axial location of the end of the effective cutting length L.sub.E coincides with section VI-VI).

[0072] The outer edge of the cutting portion 14 is substantially cylindrical. More precisely, noting this is a preference, the diameter D.sub.E of the end mill, when magnified to a magnitude of microns, is greater at the cutting end face 16 than at locations closer to the shank 12. Stated differently, the diameter D.sub.E decreases with increasing proximity to the shank 12. Thus D.sub.EI is larger than D.sub.EII, which in turn is larger than D.sub.EIII, which in turn is larger than D.sub.EIV, which in turn is larger than D.sub.EV. Also, in some embodiments, the cutting teeth 20A, 20B, 20C, 20D, 20E, 20F, 20G can all extend equally radially outwardly to establish the diameter D.sub.E.

[0073] As shown from the unbroken appearance of the teeth 20 in FIG. 1, the teeth 20 are non-serrated.

[0074] In FIG. 2, first, second, third, fourth, fifth, sixth and seventh index angles IA1, IA2, IA3, IA4, IA5, IA6, IA7 are shown.

[0075] Referring to FIG. 1, aside from the cutting end face 16, i.e. the front of the effective cutting length L.sub.E, and section VI-VI at the rear end of the effective cutting length L.sub.E, intermediary axial locations or sections (or views of a plane perpendicular to the central rotation axis A.sub.R) have been chosen for explanatory purposes. For example: section corresponds to an axial location or section rearward of the cutting end face 16 by a quarter of the effective cutting length L.sub.E; section IV-IV corresponds to an axial location or section rearward of section by a quarter of the effective cutting length L.sub.E and therefore represents the middle of the effective cutting length L.sub.E; section V-V corresponding to an axial location or section rearward of section IV-IV by a quarter of the effective cutting length L.sub.E; and section VI-VI is an axial location or section rearward of section V-V by a quarter of the effective cutting length L.sub.E. Accordingly, a front half 24 of the effective cutting length L.sub.E is from the section IV-IV to the cutting end face 16, and a rear half 26 of the effective cutting length L.sub.E is from the section IV-IV to the section VI-VI.

[0076] Using FIG. 3 for ease of visibility, some further features are identified. Each tooth 20 comprises: first, second, third, fourth, fifth, sixth and seventh rake surfaces (28A, 28B, 28C, 28D, 28E, 28F, 28G); first, second, third, fourth, fifth, sixth and seventh relief surfaces (30A, 30B, 30C, 30D, 30E, 30F, 30G) succeeding each adjacent rake surface 28 and having first, second, third, fourth, fifth, sixth and seventh relief surface widths (W1, W2, W3, W4, W5, W6, W7); first, second, third, fourth, fifth, sixth and seventh cutting edges (32A, 32B, 32C, 32D, 32E, 32F, 32G) formed at respective intersections of the rake and relief surfaces 28, 30; first, second, third, fourth, fifth, sixth and seventh relief edges (34A, 34B, 34C, 34D, 34E, 34F, 34G) at a succeeding end of each relief surface 30; and first, second, third, fourth, fifth, sixth and seventh flute surfaces (36A, 36B, 36C, 36D, 36E, 36F, 36G) succeeding each relief edge (34A, 34B, 34C, 34D, 34E, 34F, 34G). Each flute surface 36 extends in the succeeding direction D.sub.S until it reaches an adjacent first, second, third, fourth, fifth, sixth or seventh nadir (38A, 38B, 38C, 38D, 38E, 38F, 38G).

[0077] To explain measurement of the relief surface widths W with a specific example, the first relief surface W1 is measured from the first cutting edge 32A to the relief edge 34A, the relief edge 34A in this example constituting a discontinuity point in a plane perpendicular to the rotation axis A.sub.R. To elaborate a radial line is extended from the central rotation axis A.sub.R to the first cutting edge 32A and a second line parallel to the radial line is drawn intersecting the relief edge 34A, and the distance between the two lines is measured to provide the width. As shown, the first relief surface W1 is succeeded by the first flute surface 36A which has a different slope. It is understood that in cross-sections along the effective cutting length L.sub.E, the relief surfaces 30 are recessed from the footprint of the cutting diameter D.sub.E, except at the cutting edges 32. In a case where the relief surface 30 comprises a plurality of sub-relief surfaces (not shown) the relief edge (i.e. the discontinuity in a cross sectional view) which should be considered for width measurement is that which is closest to the nadir of the flute (and not the cutting edge).

[0078] Each tooth 20 comprises a tooth area A.sub.T. The tooth area A.sub.T is defined between a first radial line L.sub.R1 extending from the cutting edge 32 to the central rotation axis A.sub.R and a second radial line L.sub.R2 extending from the central rotation axis A.sub.R to the nadir 38 succeeding the cutting edge 32. To explain with a specific example, a third tooth area A.sub.T3, shown for ease of visibility with hatching, is defined between a first radial line L.sub.R1 extending from the third cutting edge 32C to the central rotation axis A.sub.R and a second radial line L.sub.R2 extending from the central rotation axis A.sub.R to the third nadir 38C succeeding the third cutting edge 32C.

[0079] In the present example, in the section view shown in FIG. 3, the teeth with the largest tooth areas are the second, third and sixth teeth (20B, 20C, 20F) (which could be visually appreciated by drawings radial lines on each one as explained with respect to the third tooth 20C in the preceding paragraph). Each of the second, third and sixth teeth (20B, 20C, 20F) have a tooth area A.sub.T greater than an average tooth area A.sub. (not shown). An average tooth area A.sub. can be calculated with the equation A.sub.=A.sub.Ti/n (where Ti represents the value of a specific tooth area and n is the number of teeth).

[0080] The teeth 20 each have a radial rake angle R, measurable between a radial line extending from the central rotation axis A.sub.R to the cutting edge 32 and a tangent line L.sub.T extending tangentially from the associated rake surface 28. To explain with a specific example, the first radial rake angle R.sub.A, is measurable between a first radial line L.sub.RA and a first tangent line L.sub.TA from the first rake surface 28A.

[0081] In the present example, in the section view shown in FIG. 3, the teeth with the smallest radial rake angles are the third and sixth teeth (20C, 20F). The teeth with the largest radial rake angles are the second, fourth and seventh teeth (20B, 20D, 20G). The teeth having radial rake angles larger than the smallest radial rake angles and smaller than the largest radial rakes angles are the first and fifth teeth (20A, 20E).

[0082] In this example, the third and sixth teeth (20C, 20F) have radial rake angles of 6, the second, fourth and seventh teeth (20B, 20D, 20G) have radial rake angles of 12, and the first and fifth teeth (20A, 20E) have radial rake angles of 9. An average radial rake angle R.sub. can be calculated with the equation R.sub.=R.sub.i/n (where R.sub.i represents the value of a specific radial rake angle and n is the number of teeth). In this example the average radial rake angle is calculated as follows: R.sub.=(6+6+12+12+12+9+9)/7=9.43. Therefore, in this example, the second, fourth and seventh teeth (20B, 20D, 20G) have radial rake angles greater than the average radial rake angle and the remainder of teeth have radial rake angles smaller than the average radial rake angle.

[0083] In the present example, the flutes with the largest helix angles H are the third and sixth flutes (22C, 22F). The flutes with the smallest helix angles are the first and fifth flutes (22A, 22E). The flutes having helix angles larger than the smallest helix angles and smaller than the largest helix angles are the second, fourth and seventh flutes (22B, 22D, 22G). In this example, the third and sixth flutes (22C, 22F) have helix angles of 37, the second, fourth and seventh flutes (22B, 22D, 22G) have helix angles of 36, and the first and fifth flutes (22A, 22E) have helix angles of 35. An average helix angle H.sub. can be calculated with the equation H.sub.=H.sub.i/n (where H.sub.i represents the value of a specific helix angle and n is the number of teeth). In this example the average helix angle is calculated as follows: H.sub.=(37+37+36+36+36+35+35)/7=36.

[0084] Therefore, in this example, the second, fourth and seventh flutes (22B, 22D, 22G) have helix angles equal to the average helix angle, the first and fifth flutes (22A, 22E) have helix angles smaller than the average helix angle, and the third and sixth flutes (22C, 22F) have helix angles larger than the average helix angle.

[0085] Since the third and sixth teeth have radial rake angles that are smaller than average and their associated third and sixth flutes have helix angles that are larger than average, the third and sixth teeth can be considered to have radial rake angles that are negatively correlated with their respective associated third and sixth flutes' helix angles.

[0086] Each flute 22 has a flute depth F. The flute depth F is measurable between the nadir 38 of the associated flute 22 and the diameter D.sub.E in the associated sectional view. The flute depth F can increase with increasing distance from the shank 12.

[0087] In the present example, referring to FIG. 2, a first flute depth F6I of the sixth flute 22F, is shown at the cutting end face 16, and at this axial location has a largest flute depth, when compared with locations closer to the shank 12. Notably, the first flute depth F6I is measured between the seventh nadir 38G (noting that the nadirs are numbered in common with the preceding tooth) and the diameter D.sub.E. The different flute depths of the sixth flute 22F are exemplified in the remaining drawings. Each flute depth closer to the shank 12 has a relatively smaller magnitude than locations closer to the cutting end face 16. For example, the first flute depth F6I at the cutting end face 16 is deeper (i.e. greater in magnitude than a second flute depth F6II of the sixth flute 22F in FIG. 3. Similarly, the second flute depth F6II is deeper than a third flute depth F6III in FIG. 4, which in turn is deeper than a fourth flute depth F6IV in FIG. 5, which in turn is deeper than a fifth flute depth F6V in FIG. 6.

[0088] Reverting to FIG. 2, index angles are shown measurable between cutting edges 32. For example, a first index angle IA1 is measurable between the first cutting edge 32A and the second cutting edge 32B. Similarly, second, third, fourth, fifth, sixth and seventh index angles (IA2, IA3, IA4, IA5, IA6, IA7) are shown.

[0089] In the present example, the first index angle IA1 is equal to 57.4, the second index angle IA2 is equal to 57.9, the third index angle IA3 is equal to 45.3, the fourth index angle IA4 is equal to 45, the fifth index angle IA5 is equal to 63.9, the sixth index angle IA6 is equal to 45.2, and the seventh index angle IA7 is equal to 45.3.

[0090] Reverting to FIG. 3, first, second, third, fourth, fifth, sixth and seventh index angles (D31, D32, D33, D34, D35, D36, D37) also correspond to the first, second, third, fourth, fifth, sixth and seventh flutes (22A, 22B, 22C, 22D, 22E, 22F, 22G) but have different values to the first, second, third, fourth, fifth, sixth and seventh index angles (IA1, IA2, IA3, IA4, IA5, IA6, IA7) in FIG. 1 resulting from the unequal helix values.

[0091] Notably, the helix angles and index angles can be advantageously configured to approach equality (which in this case is 51.4, i.e. 360 divided by the no. of teeth) at the middle of the effective cutting length. That is to say in FIG. 3 the index angles D3 are closer to 51.4 than the index angles IA in FIG. 2, and the first, second, third, fourth, fifth, sixth and seventh index angles (IC1, IC2, IC3, IC4, IC5, IC6, IC7) in FIG. 4 are closer, or equal, to 51.4 than in FIG. 3.

[0092] Notably, the helix angles and index angles are configured to diverge from the equal or near equal values at the middle of the effective cutting length. That is to say in FIG. 5 the index angles (ID1, ID2, ID3, ID4, ID5, ID6, ID7) are further from the value 51.4 than the corresponding index angles IC in FIG. 4.

[0093] The divergence of the index angles from equality can be approximately the same (at least in absolute magnitude) in FIGS. 3 and 5, and also in FIGS. 2 and 6.

[0094] Test results for the above-described end mill by far surpassed performance of comparative end mills tested (on steels having a hardness of 38-65 HRc, with a chip width of up to 10% of the end mill diameter, and at a depth of 4D). A level of surface finish acceptable according to industry standards for finish is Ra=0.4 m, and Ra=0.3 m was achieved even at a depth of 4D. Similarly, the end mill performed successfully under trochoidal milling conditions, and even on stainless steel. While testing has not yet been completed, successful testing was achieved even for chips of up to 25% of the end mill diameter. Thus far, all testing even for varied conditions and materials has been successful.

[0095] While each of the features undoubtedly contributed to improved performance, each of a number of specific improvements are believed to individually provide improved performance even for different application end mills.

[0096] For example, one design feature thought to particularly contribute to the end mill's performance is that at least one, and preferably each, of the third and sixth teeth (20C, 20F), which have a radial rake angle of 6 (i.e. a smaller radial rake angle value than the average radial rake angle of 9.43, and preferably the smallest radial rake angle out of the rake angle set of 6, 9 and 12) are each preceded by a flute, i.e. third and sixth flutes 22C, 22F having a helix angle of 37 (i.e. a helix angle value larger than the average helix angle of 36, and preferably the largest helix angle value out of the helix angle set of 35, 36 and 37).

[0097] It is also noted that the converse arrangement is not necessarily detrimental, i.e. a tooth with the largest radial rake angle (i.e. 12, which reduces radial cutting force required) does not necessarily have to be associated with a preceding flute having the smallest helix angle (i.e. 35) but can beneficially be associated with a preceding flute of a larger helix angle (i.e. 36, requiring less radial cutting force than a helix angle of 35).

[0098] Yet another design feature providing a notable independent contribution is the provision of radial rake angles with significantly different values. To offset a particularly long effective cutting length and increasing flute depth, the radial rake angles are different by 2 or more (and in this example by 3). It is believed beneficial, however, for the radial rake angle values to not be overly different so as not to overly vary cutting forces on a particular tooth thereby increasing wear.

[0099] For explanative purposes it is noted that the exemplary radial rake angle set includes seven values, namely 6, 6, 12, 12, 12, 9, 9. It is noted that one tooth having a radial rake angle value of 9 differs from the teeth having radial rake angles of 6 by 3, and also differs from the teeth having radial rake angles of 12 by 3. However, it does not differ at all from the other tooth having an identical value of 9. It can now be understood that the tooth having a radial rake angle value of 9, has a radial rake angle value which differs by at least 2 (in this case differing by exactly 3) from all other teeth with non-identical radial rake values (i.e. this statement thereby excludes the one other tooth having an identical value of 9).

[0100] Such feature is thought to particularly allow difficult to achieve deep shouldering, successfully tested at 4D but believed to be possible to be feasible at up to, and perhaps even more than 6D.

[0101] The deep shouldering capability is believed to be assisted by other design features such as the index angle arrangement which on the one hand comprises different index values to reduce vibration and on the other hand converges towards equality at the center of the end mill and diverges again to not detrimentally space the teeth.

[0102] A similar design contribution can be understood by the helix variance being tightly restricted to a close set of values (in this case the variance being a total of 3 between all flutes). While varying helix angles benefits vibration reduction, this variance was restricted to produce an end mill with a particularly long effective cutting length, and was subsequently compensated with a relatively larger radial rake variance (radial rake variation typically being believed to be less effective in reducing vibration than helix variation).

[0103] Similar to other factors (e.g. the radial rake angles, helix angles, index angles), the flute depths are also varied to reduce vibration, but again within a limited amount to not detriment the end mill.

[0104] Yet another design feature incorporated to reduce vibration was to vary tooth width (i.e. provision of different relief surface widths). Tooth widths are typically configured to be as large as possible to provide necessary strength for a cutting action and reduction of a tooth width could therefore easily be considered detrimental. Nonetheless, to reduce vibration this variation was incorporated and offset by reducing the relief surface widths only on teeth with larger tooth areas.

[0105] The description above includes an exemplary embodiment which does not exclude non-exemplified embodiments from the claim scope of the present application.