Design of Unequal Division Alloy End Mills

Release time:

2025/11/14

Unequal Cutting Design

There are three types of unequal cutting designs: unequal pitch teeth, unequal helix angles, and unequal lead. The purpose of these designs is to enable high-speed machining, achieve high productivity, ensure stable and reliable surface quality, extend tool life, and ultimately reduce costs for tool users.

01 Unequal Pitch Teeth
By having the radial cutting edges engage the workpiece at different times, different vibration frequencies are generated, which helps suppress chatter.

02 Unequal Lead
By varying the helix angles of each cutting edge within different ranges, more micro-frequencies are generated during cutting. This interference reduces the chance of resonance, thereby providing a vibration-damping effect. With this design, tools can perform large-feed and high-speed cutting. Strong tool holders are recommended for optimal performance.

Example Design
In recent years, CAM software capabilities have improved significantly, giving rise to high-speed trochoidal milling methods. For this machining method, the tool can be designed as follows:

Material Selection: Choose tungsten carbide as the tool material.
Number of Flutes: Consider 5, 6, or 7 flutes to increase cutting feed rates.
Helix Angle: A larger helix angle makes the chip flute denser and affects chip evacuation. A smaller helix angle increases cutting force. Therefore, a helix angle of 38°–48° is recommended.
Unequal Pitch and Helix Design: Incorporate unequal pitch teeth and unequal helix angles to reduce vibration for high-speed cutting.
Chip Breaker and Core Thickness: For deep axial cutting with narrow widths, chip breakers can be added on the cutting edge, and the core thickness can be designed as 70%–75% of the tool diameter to increase rigidity and reduce deflection.
Corner Design: The tool tip can have a chamfer (C) or radius (R) to increase tool life.
Cutting and Relief Angles: Determined by the material being machined.
Coating: Choose the appropriate coating formula based on application.