Cemented carbide corner radius end mill with continuously curved rake ridge and helical flute design

Abstract

A corner radius end mill includes a tooth adjacent a helically extending flute. The tooth includes axial and radial relief surfaces connected by a corner relief surface, as well as rake surface having a rake ridge. The rake ridge is continuously curved from a bisector line until at least an axial location rearward of the corner relief surface.

Claims

1. A cemented carbide corner radius end mill (10) having a rotation axis (12) defining forward and rearward directions (D.sub.F, D.sub.R), and comprising: front and rear ends (14, 16) and a peripheral surface (18) extending therebetween; a cutting portion (20) extending rearwardly from the front end (14); and a shank portion (22) located rearward of the cutting portion (20); the cutting portion (20) having a cutting portion diameter D.sub.E at the front end (14) and an effective cutting length (L.sub.E) and comprising: integrally formed teeth (24) extending from the front end (14) in the rearward direction, along the peripheral surface (18); and a helical flute (26) located between each pair of adjacent teeth (24) and having a helix angle H fulfilling the condition: 25??H?60?; an index angle S subtended between each pair of adjacent teeth (24); each tooth (24) comprising: a relief surface (28); a rake surface (30); a cutting edge (32) formed at an intersection of the relief and rake surfaces (28, 30); and a corner (34) comprising a circular arc profile defining a portion (36) of a circle (I.sub.C) having a circle center point (C.sub.C), a circle radius R.sub.C, axial and radial tangent lines (L.sub.A, L.sub.R), and a bisector line (L.sub.B); the relief surface (28) comprising: an axial relief surface (28A) at the front end (16); a radial relief surface (28B) at the peripheral surface (18); and a corner relief surface (28C) connecting the axial and radial relief surfaces (28A, 28B); the rake surface (30) comprising: a rake cutting sub-surface (30A) extending adjacent the cutting edge (32); a rake recessed sub-surface (30B); and a rake ridge (30C) formed at an intersection of the rake cutting and rake recessed sub-surfaces (30A, 30B) wherein the rake cutting sub-surface (30A) is closer to the cutting edge (32) than the rake recessed sub-surface (30B); the cutting edge (32) comprising: an axial sub-edge (32A) at the front end (14) extending to the axial tangent line (L.sub.A); a corner sub-edge (32B) extending from the axial tangent line (L.sub.A) to the radial tangent line (L.sub.R); and a radial sub-edge (32C) extending rearward from the radial tangent line (L.sub.R); between the rake ridge (30C) and the cutting edge (32): a radial cutting sub-surface width W.sub.R is measurable along the radial tangent line (L.sub.R); a bisector cutting sub-surface width W.sub.B is measurable along the bisector line (L.sub.B); and an axial cutting sub-surface width W.sub.A is measurable along the axial tangent line (L.sub.A); wherein the rake ridge (30C) of one or more of the teeth (34) is continuously curved from the bisector line (L.sub.B) until at least an axial location rearward of the corner relief surface (28C); wherein the radial cutting sub-surface width W.sub.R and bisector cutting sub-surface width W.sub.B fulfill the condition: 0.9W.sub.B?W.sub.R?1.1W.sub.B.

2. The end mill (10) according to claim 1, wherein, at an intersection of the radial and corner relief surfaces (28B, 28C), the radial and corner sub-edges (32B, 32C) form an external relief angle ? fulfilling the condition: 170????180?.

3. The end mill (10) according to claim 2, wherein the external relief angle ? fulfills the condition: 178????180?.

4. The end mill (10) according to claim 1, wherein each cutting sub-surface width W measurable between the rake ridge and the cutting edge, and taken between the radial tangent line and the bisector line, fulfills the condition: 0.9W.sub.B?W?1.1W.sub.B.

5. The end mill (10) according to claim 1, wherein the radial cutting sub-surface width W.sub.R and the axial cutting sub-surface width W.sub.A fulfill the condition: 0.9W.sub.A?W.sub.R?1.1W.sub.A.

6. The end mill (10) according to claim 1, wherein each cutting sub-surface width W measurable between the rake ridge and the cutting edge, and taken between the radial tangent line and the axial tangent line, fulfills the condition: 0.9W.sub.A?W?1.1W.sub.A.

7. The end mill (10) according to claim 1, wherein at least one cutting sub-surface width W measurable between the rake ridge and the cutting edge, and taken between the axial tangent line and the bisector line, fulfills the condition: 0.008D.sub.E?W?0.02D.sub.E.

8. The end mill (10) according to claim 7, wherein each cutting sub-surface width W taken between the axial tangent line and the bisector line, fulfills the condition: 0.008D.sub.E?W?0.02D.sub.E.

9. The end mill according to claim 8, wherein each cutting sub-surface width W measurable between the axial tangent line and the radial tangent line, fulfills the condition: 0.008D.sub.E?W?0.02D.sub.E.

10. The end mill (10) according to claim 1, wherein each rake cutting sub-surface (30A) is planar shaped.

11. The end mill (10) according to claim 1, wherein the circle radius R.sub.C fulfills the condition: R.sub.C?0.08D.sub.E.

12. The end mill (10) according to claim 1, wherein the cutting portion (20) comprises exactly either seven teeth (24) or nine teeth (24).

13. The end mill (10) according to claim 1, wherein one or more of the teeth (24) has a radial rake angle ? measurable along the radial tangent line (L.sub.R) fulfilling the condition: ?12????7?.

14. The end mill (10) according to claim 13, wherein each tooth (24) has a radial rake angle ? measurable along the radial tangent line (L.sub.R) fulfilling the condition: ?5????5?.

15. The end mill (10) according to claim 1, wherein one or more of the teeth (24) has a radial rake angle ? measurable along the radial tangent line (L.sub.R) fulfilling the condition: ?>0?.

16. The end mill (10) according to claim 1, wherein one or more of the teeth (24) has a radial rake angle ? measurable along the radial tangent line (L.sub.R) fulfilling the condition: ?<0?.

17. The end mill (10) according to claim 1, wherein, at the front end (14), fewer than one-half the index angles have the same value.

18. The end mill (10) according to claim 17, wherein each index angle S, in the middle of an effective length (L.sub.M), has a value closer to a value equal to the total number of teeth (24) divided by 360, than a value of the same index angle S at the front end (14).

19. The end mill (10) according to claim 1, wherein each tooth (24) has a rake ridge (30C) which continuously curves from the bisector line (L.sub.B) until at least an axial location rearward of the corner relief surface (28C).

20. The end mill (10) according to claim 10, wherein each tooth (24) has a rake ridge (30C) which continuously curves from the bisector line (L.sub.B) until at least an axial location rearward of the corner relief surface (28C).

21. The end mill (10) according to claim 20, wherein for each tooth, at an intersection of the radial and corner relief surfaces (28B, 28C), the radial and corner sub-edges (32B, 32C) form an external relief angle ? fulfilling the condition: 170????180?.

22. The end mill (10) according to claim 21, wherein the external relief angle ? fulfills the condition: 178????180?.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) 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:

(2) FIG. 1A is a side view of an end mill in accordance with the subject matter of the present application;

(3) FIG. 1B is a front end view of the end mill in FIG. 1A;

(4) FIG. 2A is a side view of a part of a cutting portion of a prior art end mill;

(5) FIG. 2B is an enlarged profile view of a corner designated IIB in FIG. 2A;

(6) FIG. 2C is an enlarged view of a portion designated IIC in FIG. 2A;

(7) FIG. 3A is a side view of a part of a cutting portion of the end mill in FIGS. 1A and 1B shown in a corresponding view to FIG. 2A;

(8) FIG. 3B is an enlarged profile view of a corner designated IIIB in FIG. 3A;

(9) FIG. 3C is an enlarged view of a portion designated IIIC in FIG. 3A; and

(10) FIG. 4A is a slightly rotated view of the end mill in FIG. 3A;

(11) FIG. 4B is an enlarged view of a corner designated IVB in FIG. 4A;

(12) FIG. 4C is yet another enlarged view of a corner of the end mill in FIG. 4A taken in the view shown by arrow IVA, which is at a 45? angle (shown as angle V) to the rotation axis; and

(13) FIGS. 5A and 5B are enlarged views exemplifying recessed rake sub-surfaces.

DETAILED DESCRIPTION

(14) Reference is made to FIGS. 1A and 1B, which illustrate a corner radius end mill 10, made of cemented carbide, and particularly configured for machining difficult to machine materials such as inconel.

(15) The end mill 10 is configured to rotate about a rotation axis 12, which can extend longitudinally through the center thereof and coincide with an end mill center point C.sub.E. In this example an end mill rotation direction D.sub.A is counter-clockwise in the front end view shown in FIG. 1B. The rotation axis 12 can define a forward direction D.sub.F and an opposite rearward direction D.sub.R (noting that while these directions are parallel with the rotation axis 12 they need not be coaxial therewith).

(16) The end mill 10 can comprise opposite front and rear ends 14, 16 and a peripheral surface 18 extending between the front and rear ends 14, 16.

(17) The end mill 10 can comprise a cutting portion 20 and a shank portion 22 located rearward of the cutting portion 20.

(18) The cutting portion 20 can comprise a cutting portion diameter D.sub.E, measurable at the front end 14 and an effective cutting length L.sub.E. The effective cutting length L.sub.E extends from the front end 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 23. Also exemplified is the front half of the effective cutting length, designated L.sub.H, which extends from the front end 14 to an axial location L.sub.M at the middle of the effective length L.sub.E.

(19) The cutting portion 20 comprises integrally formed teeth 24 (e.g., first, second, third, fourth, fifth, sixth and seventh teeth 24A, 24B, 24C, 24D, 24E, 24F, 24G).

(20) An index angle S (e.g., first, second, third, fourth, fifth, sixth and seventh index angles S.sub.A, S.sub.B, S.sub.C, S.sub.D, S.sub.E, S.sub.F, S.sub.G) is subtended between each pair of adjacent teeth. In the example shown all of the index angles have different values at the front end 14. Nonetheless the index angles converge towards equality (which for an end mill with seven teeth is 360?/7=51.4?) with increasing proximity to the axial location at the middle of the effective length L.sub.M and in this example then diverge therefrom.

(21) The cutting portion 20 comprises a helical flute 26 (e.g., first, second, third, fourth, fifth, sixth and seventh flutes 26A, 26B, 26C, 26D, 26E, 26F, 26G), i.e. at least extending helically adjacent to the front end 14, circumferentially located between each pair of adjacent teeth 24.

(22) Each flute 26 can have a helix angle H formed with the rotation axis 12.

(23) Referring now also to FIG. 3A, it is noted that, at least adjacent the front end 14, the end mill 10 can comprise a tapered core schematically shown by a tapering angle ?.

(24) Each tooth 24 can comprise the following generally designated portions: a relief surface 28, a rake surface 30, a cutting edge 32 formed at an intersection of the relief surface 28 and the rake surface 30, and a corner 34. It is noted that the relief surface 28 identified in FIG. 3A is the relief surface of a tooth 24 different to the tooth shown with the numerical designations of the other elements, this being only because the relief surface of the uppermost tooth in FIG. 3A is not visible in the profile view shown.

(25) In the profile view shown in FIG. 3A, during rotation of the end mill 10 about the rotation axis 12, the corner 34 presents a circular arc profile defining a portion 36 of an imaginary circle I.sub.C.

(26) Referring also to FIG. 3C, it is noted the circle I.sub.C has: a circle center point C.sub.C; axial and radial tangent lines L.sub.A, L.sub.R; axial and radial tangent points P.sub.AP, P.sub.RP located at intersections of the axial and radial tangent lines L.sub.A, L.sub.R and the cutting edge 32; a bisector line L.sub.B equally angularly spaced between the axial and radial tangent lines L.sub.A, L.sub.R.

(27) The relief surface 28 comprises different portions, namely an axial relief surface 28A (FIG. 1B) at the front end 14, a radial relief surface 28B (FIG. 3A) at the peripheral surface 18, and a corner relief surface 28C (FIG. 3C) connecting the axial and radial relief surfaces 28A, 28B.

(28) As shown in FIG. 3B, the rake surface 30 comprises different portions, namely a rake cutting sub-surface 30A extending adjacent the cutting edge 32, a rake recessed sub-surface 30B, and a rake ridge 30C formed at an intersection of the rake cutting and rake recessed sub-surfaces 30A, 30B.

(29) The cutting edge 32 comprises different portions, namely an axial sub-edge 32A at the front end 14 extending to the axial tangent line L.sub.A, a corner sub-edge 32B extending from the axial tangent line L.sub.A to the radial tangent line L.sub.R, and a radial sub-edge 32C extending rearward from the radial tangent line L.sub.R.

(30) As shown in FIGS. 4A and 4B, an axial rake angle ? is subtended between a gash surface line 33 to the rotation axis 12. The example axial rake angle ? shown is a positive angle.

(31) Similarly, shown in FIG. 4C, a corner rake angle ? is subtended between the corner sub-edge 32B and the rotation axis 12.

(32) Referring to FIGS. 5A and 5B, example rake cutting sub-surfaces 30A, rake recessed sub-surfaces 30B, and rake ridges 30C are shown. Notably each rake ridge 30C has a ridge shape, i.e., in the view shown, an apex descending to the rake cutting and rake recessed sub-surfaces 30A, 30B. This shape occurs regardless of whether the rake ridge 30C is located below a radial line 42 extending from the rotation axis 12 to the radial sub-edge 32C such as that shown in FIG. 5A (and hence exemplifying a positive radial rake angle, i.e. ?.sub.A>0?), or above the radial line 42 as exemplified in FIG. 5B (showing a negative radial rake angle, i.e. ?.sub.B<0?).

(33) Each rake cutting sub-surface 30A has an actual internal cutting angle ? having a greater value than an imaginary internal cutting angle ? associated with the rake recessed sub-surface 30B. More precisely, referring to FIG. 5B as an example, an imaginary rake extension line 38, extending the rake recessed sub-surface 30B from the rake ridge 30C intersects an imaginary relief extension line 40 which extends the radial relief surface 28B.

(34) The rake cutting sub-surfaces 30A can have a planar shape (as is understood from the straight line visible in the side views in FIGS. 5A and 5B).

(35) The rake recessed sub-surfaces 30B of each tooth can have the same shape, which can be a concave shape as shown in FIGS. 5A and 5B. Notably, the shape is recessed from the associated rake cutting sub-surface 30A so that chips which have been machined from a workpiece (not shown) can preferably pass over the rake recessed sub-surface 30B without contact, especially at points immediately adjacent the rake ridge 30C, thereby reducing heat transfer to the end mill.

(36) Reverting to FIG. 3B, cutting sub-surface widths W (e.g., W.sub.R, W.sub.B, W.sub.A) are measurable between closest points of the rake ridge 30C and the cutting edge 32. A radial cutting sub-surface width W.sub.R is measurable along the radial tangent line L.sub.R, a bisector cutting sub-surface width W.sub.B is measurable along the bisector line L.sub.B2, and an axial cutting sub-surface width W.sub.A is measurable along the axial tangent line L.sub.A.

(37) The rake cutting sub-surface 30A can comprise three distinct sub-portions. Namely, a radial sub-portion 30A1, an axial sub-portion 30A2, and a corner sub-portion 30A3. First and second curvature lines 44A, 44B may be visible to show limits of the sub-portions.

(38) Referring to FIG. 3C, a perpendicular plane S.sub.P, extending perpendicular to the rotation axis 12, can be defined at the rearmost point 45 of the corner relief surface 28C. The perpendicular plane S.sub.P defines an axial location along the rotation axis 12. The end mill 10 can then be rotated around the rotation axis 12 until the profile view shown in FIG. 3B is visible. As shown the perpendicular plane S.sub.P is also derivable in FIG. 3B even though the corner relief surface 28C is not visible, since the axial location has been noted. It will be understood that the precise axial location of the perpendicular plane S.sub.P in FIG. 3B has been added schematically for explanatory purposes only.

(39) In any case, in FIG. 3B it can be seen that the rake ridge 30C is continuously curved from the bisector line L.sub.B until at least an axial location, shown by perpendicular plane S.sub.P, rearward of the corner relief surface 28C. Indeed the rake ridge 30C is continuously curved in the entire view shown in FIG. 3B. In this context, continuously curved means that the rake ridge 30C does not contain a discontinuity.

(40) By contrast, a prior art end mill 10 is shown in FIGS. 2A to 2C with basically corresponding elements having the same reference characters suffixed with an apostrophe (). It is noted that instead of three distinct sub-portions 30, the corner 34 has two sub-portions, namely a radial sub-portion 30A1 and a single corner-axial sub-portion 30A4 which is shown to meet the radial sub-portion 30A1 at a single curvature line 44C. An corner-axial rake ridge portion 30C 1 extending along the single corner-axial sub-portion 30A4 does not continuously curve to the connected radial rake ridge portion 30C2 as shown by the discontinuity 46. Notably a perpendicular plane S.sub.P, which locates the axial location of the rearmost point 45 of the corner relief surface 28C (FIG. 2C), is located rearward of the discontinuity 46.

(41) It will also be understood that an external relief angle ? (FIG. 3C), measured between the corner and radial sub-edges 32B, 32C can be advantageously closer to 180? than the comparatively smaller external relief angle ? (FIG. 2C) of the prior art tool 10.

(42) The description above includes an exemplary embodiment and details, and does not exclude non-exemplified embodiments and details from the claim scope of the present application.