Patent Description:
An end mill described in Patent Document <NUM> has been known as an example of rotary tools for carrying out the milling process on a workpiece. Examples of the workpiece include FRP (Fiber Reinforced Plastic), such as CFRP (Carbon Fiber Reinforced Plastic). The end mill described in Patent Document <NUM> includes a main cutting edge and a nick cutting edge disposed at a reverse helix angle twisted oppositely to a helix angle of the main cutting edge. A difference between the number of gullets of the main cutting edge and the number of groove lines of the nick cutting edge is set to be <NUM> or less. With the end mill described in Patent Document <NUM>, cutting performance for fibers included in the FRP can be enhanced because of the main cutting edge and the nick cutting edge which are twisted in opposite directions.

Because chip discharge performance may degrade in the nick cutting edge disposed at the reverse helix angle, there is a desire to increase the reverse helix angle of a nick flute located along the nick cutting edge. It is however difficult to increase the reverse helix angle of the nick flute because the difference between the number of gullets of the main cutting edge and the number of groove lines of the nick cutting edge is <NUM> or less in the end mill described in Patent Document <NUM>.

Attempts to decrease the number of groove lines of the nick cutting edge are conceivable to increase the reverse helix angle of the nick flute. However, a mere decrease in the number of groove lines of the nick cutting edge may cause a failure in obtaining the effect of cutting fibers by the nick cutting edge as described in Patent Document <NUM>.

Hence, there has been a demand for a rotary tool that ensures a proper discharge of chips while appropriately cutting fibers in a workpiece including the fibers, such as FRP.

<CIT> describes a rotary tool having five flutes. <CIT> describes a rotary tool having four flutes.

A rotary tool in one of embodiments includes a main body having a circular columnar shape, including a rotation axis and extending from a first end to a second end. The main body includes a plurality of first flutes and a first cutting edge. The first flutes are located on an outer periphery of the main body and go toward a rear side in a rotation direction of the rotation axis at a helix angle θ1 as going toward the second end. The first cutting edge is located on at least a part of a ridge line where the outer periphery of the main body intersects with the first flutes. The main body also includes a plurality of second flutes and a second cutting edge. The second flutes are located on the outer periphery of the main body. The second flutes go toward a front side in the rotation direction of the rotation axis at a reverse helix angle θ2 as going toward the second end. The second flutes intersect with the first flutes. The second cutting edge is located on at least a part of a ridge line where the outer periphery of the main body intersects with the second flutes. The θ2 is larger than the θ1, m><NUM>, m-n≥<NUM>, and m and n are coprime numbers where m is the number of the first flutes and n is the number of the second flutes.

A rotary tool <NUM> in one of embodiments is described in detail below with reference to the drawings. Although the end mill <NUM> is illustrated as an embodiment of the rotary tool <NUM> in the present embodiments, the rotary tool may be, for example, a reamer without being limited to the end mill.

For the sake of description, the drawings referred to in the following illustrate, in a simplified form, main members of members constituting each of the embodiments. The rotary tools are therefore capable of including any arbitrary structural member not illustrated in the drawings referred to. Sizes of the members in each of the drawings do not faithfully represent sizes and size ratios of actual structural members.

The rotary tool <NUM> (end mill <NUM>) includes a column-shaped main body <NUM> that has a circular columnar shape, includes a rotation axis X1 and extends from a first end 3a to a second end 3b in the embodiments as illustrated in <FIG> and the like. In general, the first end 3a is called "a front end" and the second end 3b is called "a rear end. " The main body <NUM> is rotatable about the rotation axis X1 and is rotated about the rotation axis X1 in the step of cutting out a workpiece for manufacturing a cut product. Arrow X2 in <FIG> and the like indicates a rotation direction of the main body <NUM>.

The main body <NUM> is composed of a holding part <NUM> that is called "a shank" and a cutting part <NUM> that is called "a body. " The holding part <NUM> is the part to be held by, for example, a spindle in a machine tool (not illustrated). A shape of the holding part <NUM> is therefore designed according to a shape of the spindle. The cutting part <NUM> is located closer to a side of the first end 3a than the holding part <NUM>. The cutting part <NUM> is the part that is brought into contact with a workpiece and plays a major role in the cutting process of the workpiece.

The main body <NUM> includes a plurality of first flutes <NUM>, a plurality of first cutting edges <NUM>, a plurality of second flutes <NUM> and a plurality of second cutting edges <NUM> in the embodiments. The first flutes <NUM> are individually located on an outer periphery of the main body <NUM> and are twisted so as to go toward a rear side in the rotation direction X2 as going toward the second end 3b. Here, a helix angle of the first flutes <NUM> is taken as θ1. Each of the first flutes <NUM> extends straight in a developed view as illustrated in <FIG>. Although the number of the first flutes <NUM> is not limited to a specific value, it is settable to, for example, <NUM>-<NUM>.

Like the first flutes <NUM>, the second flutes <NUM> are also located on the outer periphery of the main body <NUM>. Contrary to the first flutes <NUM>, the second flutes <NUM> are twisted so as to go toward a front side in the rotation direction X2 as going toward the second end 3b. Here, a reverse helix angle of the second flutes <NUM> is taken as θ2. Each of the second flutes <NUM> extends straight in the developed view as illustrated in <FIG>. Although the number of the second flutes <NUM> is not limited to a specific value, it is settable to, for example, <NUM>-<NUM>.

The first flutes <NUM> intersect with second flutes <NUM> on the outer periphery of the main body <NUM>, and the second flutes <NUM> are configured to be divided by the first flutes <NUM> in the embodiments. Because the second flutes <NUM> are divided by the first flutes <NUM>, the single second flute 13a is composed of a plurality of second flute elements 13aa being divided by the first flutes <NUM> as in one embodiment illustrated in <FIG>. The second flute elements 13aa are located along a single straight line because the second flutes <NUM> extend straight in the developed view.

The first cutting edges <NUM> are located on at least a part of a ridge line where the outer periphery of the main body <NUM> intersects with the first flutes <NUM>. Although the first cutting edges <NUM> are individually located on the entirety of the ridge line where the outer periphery of the main body <NUM> intersects with the first flutes <NUM> in the embodiments, the first flutes <NUM> are not necessarily located on the entirety of the ridge line where the outer periphery of the main body <NUM> intersects with the first flutes <NUM>. Each of the first cutting edges <NUM> is a portion of a cutting edge generally called an outer peripheral cutting edge. Specifically, the first cutting edge <NUM> is also a portion of the cutting edge which plays a major role in the cutting process of the workpiece by using the end mill <NUM>, and is also called a main cutting edge.

Because the first flutes <NUM> intersect with the second flutes <NUM> on the outer periphery of the main body <NUM>, the first cutting edges <NUM> servable as the main cutting edge are divided by the second flutes <NUM>. The second flutes <NUM> are therefore generally called nick flutes. Because the first cutting edges <NUM> are divided by the second flutes <NUM>, it is possible to reword that the single cutting edge 11a located on the ridge line where the single first flute <NUM> intersects with the outer periphery of the main body <NUM> is composed of a plurality of first cutting edge elements 11aa being divided by the second flutes <NUM>.

The second flutes <NUM> extend in a direction inclined at the reverse helix angle θ2 instead of a direction orthogonal to the rotation axis X1 in the embodiments. Accordingly, the second cutting edge <NUM> are located on at least a part of the ridge line where the outer periphery of the main body <NUM> intersects with the second flutes <NUM>.

Although the second cutting edges <NUM> are individually located on the ridge line where the outer periphery of the main body <NUM> intersects with the second flutes <NUM> in the embodiments, the second cutting edges <NUM> are not necessarily located on the entirety of the ridge line where the outer periphery of the main body <NUM> intersects with the second flutes <NUM>. The second cutting edges <NUM> are also called nick cutting edges because the second cutting edges <NUM> are located on the ridge line where the second flutes <NUM> also called nick flutes intersect with the outer periphery of the main body <NUM>.

Because the first flutes <NUM> intersect with second flutes <NUM> on the outer periphery of the main body <NUM>, the second cutting edges <NUM> servable as the nick cutting edges are divided by the first flutes <NUM>. Because the second cutting edges <NUM> and the second flutes <NUM> are divided by the first flutes <NUM>, it is possible to reword that the single second cutting edge 15a located on the ridge line where the single second flute <NUM> intersects with the outer periphery of the main body <NUM> is composed of a plurality of second cutting edge elements 15aa being divided by the first flutes <NUM>.

If the workpiece is a material including fibers, a part of the fibers may remain without being cut out by the first cutting edges <NUM> because the first cutting edges <NUM> are twisted at the helix angle θ1. However, because the second cutting edges <NUM> are twisted at the reverse helix angle θ2, it is possible to cut out the remaining fibers by the second cutting edges <NUM>.

Specifically, the reverse helix angle θ2 of the second flutes <NUM> is larger than the helix angle θ1 of the first flutes <NUM> in the end mill <NUM> of the embodiments. This contributes to enhancing discharge performance for chips generated on the second cutting edges <NUM>. Although specific values of θ1 and θ2 are not limited to predetermined values, for example, θ1 is settable to a value larger than <NUM>° and smaller than <NUM>°. If θ1 is a value smaller than <NUM>°, a large area of an outer peripheral surface of the main body <NUM> can be ensured to enhance stiffness of the main body <NUM>. In particular, if θ1 is larger than <NUM>° and smaller than <NUM>°, it is possible to further enhance the chip discharge performance and the stiffness of the main body <NUM>.

If θ2 is larger than <NUM>°, chips generated on the second cutting edges <NUM> can be sent out to the rear side in the rotation direction X2 in the second flutes <NUM>, thereby making it easier for the chips to flow to the first flutes <NUM>. This leads to the enhanced discharge performance for the chips generated on the second cutting edges <NUM>. If θ2 is larger than <NUM>°, an angle in a radial direction, namely, a direction orthogonal to the rotation axis X1 becomes small. Therefore, during the cutting process of the workpiece including fibers, such as FRP, it becomes easy to cut out the fibers. In particular, if θ2 is larger than <NUM>° and smaller than <NUM>°, the chip discharge performance can be further enhanced, and it becomes easier to cut out the fibers.

When the number of the first flutes <NUM> is indicated by "m" and the number of the second flutes <NUM> is indicated by "n" in the end mill <NUM> of the embodiments, these numbers "m" and "n" satisfy relationships of m><NUM> and m-n≥<NUM> and are coprime numbers. In the embodiment illustrated in <FIG>, m=<NUM> (><NUM>) and n=<NUM> (m-n=<NUM>-<NUM>=<NUM>≥<NUM>). The embodiment illustrated in <FIG> is a mere embodiment, and there is no problem, for example, even if m=<NUM> and n=<NUM>.

Because the number of the first flutes <NUM> is <NUM> or more, a cutting load applied to the first cutting edges <NUM> respectively located along the first flutes <NUM> can be dispersed to avoid excessive collection of the cutting load on the specific first cutting edge <NUM>, thereby enhancing the durability of the main body <NUM>. Additionally, because the number of the second flutes <NUM> is three or more below the number of the first flutes <NUM>, it becomes possible to increase the reverse helix angle of the second flutes <NUM>.

If "m" and "n" are not coprime numbers but have a common divisor except <NUM>, positions of the second flutes <NUM> are synchronized with one another, and a region cut out only by the first cutting edge <NUM> is likely to increase. However, "m" and "n" are coprime numbers in the embodiments. Accordingly, because the positions of the second flutes <NUM> do not tend to synchronize with one another, it is possible to reduce or eliminate the region cut out only by the first cutting edges <NUM> even if the number of the second flutes <NUM> is <NUM> or more below the number of the first flutes <NUM>.

Thus, with the end mill <NUM> of the embodiments, the effect of cutting out the fibers by the second cutting edges <NUM> can be well provided while enhancing the discharge performance of chips generated on the second cutting edges <NUM> by decreasing the number of the second flutes <NUM> and by increasing the reverse helix angle of the second flutes <NUM>.

The end mill <NUM> is a tool used by right rotation in the embodiments. Therefore, the first flutes <NUM> and the first cutting edges <NUM> are right twist, and the second flutes <NUM> and the second cutting edges <NUM> are left twist. The end mill <NUM> is, however, not limited to the above embodiments. There is no problem, for example, even if the end mill <NUM> is a tool used by left rotation in which the first flutes <NUM> and the first cutting edges <NUM> are left twist and the second flutes <NUM> and the second cutting edge <NUM> are right twist.

Although widths and depts of the first flutes <NUM> and the second flutes <NUM> are not individually limited to predetermined values, for example, the width of each of the first flutes <NUM> may be larger than the width of each of the second flutes <NUM> in a side view. In cases where the first cutting edges <NUM> are the main cutting edge and the second cutting edges <NUM> are the nick cutting edges, the amount of chips generated by the first cutting edge <NUM> is likely to be larger than the amount of chips generated by the second cutting edges <NUM>. However, if the width of each of the first flutes <NUM> is larger than the width of each of the second flutes <NUM> in the above configuration, it is possible to enhance the chip discharge performance in the end mill <NUM>.

Alternatively, a width W2 of each of the second flutes <NUM> may be smaller than a distance W1 between the first flutes <NUM> adjacent to each other in the rotation direction X2 of the rotation axis X1 in the first flutes <NUM> as in the embodiment illustrated in <FIG>. In this case, a shape of the second flute <NUM> located between the first flutes <NUM> adjacent to each other in the rotation direction X2 of the rotation axis X1 becomes a long and narrow shape in a direction along the reverse helix angle θ2.

In cases where a workpiece is a material including fibers, the second cutting edges <NUM> are used mainly for cutting out fibers remaining without being cut out by the first cutting edge <NUM>. If the second flutes <NUM> include the long and narrow shape as described above, a movable region for the remaining fibers tends to be restricted by the second flutes <NUM>, and it therefore becomes easy to cut them out by the second cutting edges <NUM>. This leads to a well finished surface of the workpiece.

Furthermore, if a depth of each of the second flutes <NUM> is larger than the width of each of the second flutes <NUM>, space for discharging chips in the second flutes <NUM> can be ensured to enhance chip discharge performance in the second flutes <NUM>.

In cases where the second cutting edges <NUM> are overlapped with an orthogonal line to the rotation axis X1 in an end portion of the first cutting edge element 11aa which is located at a side of the second end 3b in a side view, it is easy to stably cut out the fibers included in the workpiece, thus leading to a further improved finished surface of the workpiece.

Although dimensions of the main body <NUM> are not limited to specific values in the embodiments, for example, a diameter (outer diameter) D of the main body <NUM> is settable to <NUM>-<NUM>, and a length in the direction along the rotation axis X1 of the cutting part <NUM> is settable to approximately <NUM>-<NUM> Dmm.

The outer diameter of the main body <NUM> may be constant or changed from a side of the first end 3a to a side of the second end 3b. For example, the outer diameter of the main body <NUM> may become smaller from the side of the first end 3a to the side of the second end 3b.

Examples of material constituting the main body <NUM> include metal, cemented carbide, cermet and ceramics. Examples of the metal include stainless steel and titanium. Examples of composition of the cemented carbide include WC (tungsten carbide)-Co(cobalt), WC-TiC(titanium carbide)-Co, WC-TiC-TaC(tantalum carbide)-Co, and WC-TiC-TaC-Cr<NUM>C<NUM>(chromium carbide)-Co. Here, WC, TiC, Tac, and Cr<NUM>C<NUM> are hard particles, and Co is a binding phase.

The cermet is a sintered composite material obtained by compositing metal into a ceramic ingredient. A specific example of the cermet is one which is composed mainly of a titanium compound, such as TiC and TiN (titanium nitride). Examples of the ceramics include Al<NUM>O<NUM> (aluminum oxide), Si<NUM>N<NUM> (silicon nitride), and cBN (Cubic Boron Nitride).

The main body <NUM> may be composed only of the above-mentioned material or, alternatively may be composed of a member composed of the above-mentioned material and a coating layer (not illustrated) that covers the member. Examples of material constituting the coating layer include diamond, diamond-like carbon (DLC), TiC, TiN, TiCN (titanium carbonitride), TiMN (M is at least one kind of metal element selected from metals of periodic tables <NUM>, <NUM> and <NUM>, except for Ti, and Al and Si), and Al<NUM>O<NUM>.

It is possible to improve wear resistance of the first cutting edges <NUM> and the second cutting edges <NUM> if the main body <NUM> includes the above coating layer. In particular, if the coating layer includes diamond, the end mill <NUM> demonstrates good wear resistance even if a workpiece is a ceramic material.

The coating layer can be deposited, for example, by vapor phase synthesis method. Examples of the vapor phase synthesis method include chemical vapor deposition (CVD) method and physical vapor deposition (PVD) method. A thickness of the coating layer is settable to, for example, <NUM>-<NUM>. A suitable range differs depending on a composition of the coating layer.

While the end mills <NUM> of the embodiments have been illustrated and described above, the present invention is not limited thereto but can be an arbitrary one as long as it does not depart from the scope of the present invention.

A method for manufacturing a cut product in one of embodiments is described in detail below by taking as one embodiment the case of using the end mill <NUM> in the foregoing embodiment. The method is described below with reference to <FIG> illustrate the steps of a shoulder milling of a workpiece as an embodiment of the method for manufacturing a cut product. To make it easier to visually understand, a machined surface cut out by the end mill <NUM> is illustrated by being colored in <FIG> and <FIG>.

The method for manufacturing a cut product in the embodiments includes the following steps (<NUM>) to (<NUM>).

The step (<NUM>) is to bring the end mill <NUM> near a workpiece <NUM> in Y1 direction by rotating the end mill <NUM> about the rotation axis and in an arrow X2 direction (refer to <FIG>).

The above step can be carried out, for example, by fixing the workpiece <NUM> onto a table of a machine tool with the end mill <NUM> attached thereto, and by bringing the end mill <NUM> being rotated near the workpiece <NUM>. The workpiece <NUM> and the end mill <NUM> may be brought closer to each other in this step. For example, the workpiece <NUM> may be brought near the end mill <NUM>.

The step (<NUM>) is to cut out the workpiece <NUM> by bringing the end mill <NUM> further near the workpiece <NUM> so that the end mill <NUM> being rotated comes into contact a desired position on a surface of the workpiece <NUM> (refer to <FIG>).

The first cutting edge and the second cutting edge are brought into contact with a desired position on the surface of the workpiece <NUM> in the above step. Examples of the cutting process include a grooving process and a milling process besides the shoulder milling as illustrated in <FIG>.

The step (<NUM>) is to move the end mill <NUM> away from the workpiece <NUM> in Y2 direction (refer to <FIG>).

The workpiece <NUM> and the end mill <NUM> may be separated from each other in the above step as in the case of the step (<NUM>). For example, the workpiece <NUM> may be moved away from the end mill <NUM>.

Excellent machining properties are obtainable through the steps as described above.

Claim 1:
A rotary tool (<NUM>), comprising:
a main body (<NUM>) having a circular columnar shape, comprising a rotation axis (X1) and extending from a first end (3a) to a second end (3b), wherein
the main body (<NUM>) comprises
a plurality of first flutes (<NUM>) which are located on an outer periphery of the main body (<NUM>) and go toward a rear side in a rotation direction (X2) of the rotation axis (X1) at a helix angle θ1 as going toward the second end (3b);
a first cutting edge (<NUM>) located on at least a part of a ridge line where the outer periphery of the main body (<NUM>) intersects with the first flutes (<NUM>);
a plurality of second flutes (<NUM>) which are located on the outer periphery of the main body (<NUM>) and go toward a front side in the rotation direction (X2) of the rotation axis (X1) at a reverse helix angle θ2 as going toward the second end (3b), the second flutes (<NUM>) intersecting with the first flutes (<NUM>); and
a second cutting edge (<NUM>) located on at least a part of a ridge line where the outer periphery of the main body (<NUM>) intersects with the second flutes (<NUM>), wherein
the θ2 is larger than the θ1, and characterized in that
m><NUM>, m-n≥<NUM>, and m and n are coprime numbers where m is a number of the first flutes (<NUM>) and n is a number of the second flutes (<NUM>).