Unequal Cutting Design and High-Speed Tool Optimization

Release time:

2025/11/03

Unequal Cutting Design

There are three types of unequal cutting designs: unequal division of cutting edges, unequal helix angle, and unequal pitch. The purpose of these designs is to enable high-speed machining, achieve high efficiency, maintain stable surface quality, extend tool life, and ultimately reduce costs for tool users.

01 Unequal Division of Cutting Edges

By having different radial cutting edges enter at different time points, varying frequencies are generated, which helps suppress vibration.

02 Unequal Pitch

By varying the helix angle of each tooth in different zones, more micro-frequencies are generated during cutting. This interference reduces the likelihood of resonance, effectively eliminating vibration. As a result, the tool can achieve high feed rates and high-speed cutting. In this case, it is recommended to use a strong tool holder for clamping.

Example Design

In recent years, the capabilities of CAM software have improved significantly, giving rise to high-speed trochoidal machining. Tool designs are adapted for this machining method as follows:

Selection of tungsten carbide material.
Considering the number of teeth, tools can be designed with 5, 6, or 7 flutes to increase feed rates.
Helix angle affects chip evacuation: larger helix angles result in denser flutes and may influence chip removal, while smaller helix angles increase cutting forces. It is recommended to design the helix angle in the 38°–48° range.
For high-speed cutting tools, the concepts of unequal division of cutting edges and unequal helix angle can be incorporated to reduce vibration.
As the machining method involves deep axial cuts and narrow widths, chip breakers can be added to the cutting edges, and core thickness can be designed at 70%–75% of the diameter to enhance rigidity and reduce tool deflection.
The tool tip can be designed with a C-angle or R-angle to extend tool life.
Cutting angles and clearance angles should be determined according to the material being machined.
Appropriate coating formulas should be selected.