The tooth profile design of industrial-use tree-shaped tungsten carbide burrs is a key factor influencing the cutting efficiency of different materials. It directly determines the machining results for each material by altering the force distribution, chip evacuation, and energy transfer during the cutting process. As the primary structure of industrial-use tree-shaped tungsten carbide burrs that contacts the material being cut, its shape must be tailored to the material's hardness, toughness, and brittleness to minimize resistance, avoid stuttering, and achieve efficient machining. Whether working with metals, alloys, or composite materials, the rationality of tooth profile design directly impacts material removal per unit time and machining stability.
The sharpness of the tooth profile and the cutting edge angle significantly influence the cutting efficiency of hard materials. For high-hardness materials such as hardened steel and cemented carbide, the teeth require sufficiently sharp cutting edges and a well-designed rake angle to minimize resistance during entry. Sharp tooth edges quickly penetrate the material surface, while an appropriate rake angle directs cutting forces, concentrating the energy on shearing the material rather than unnecessary deformation. Tooth profiles that are too rounded or have an inappropriate rake angle will create strong pressure on hard materials during cutting, increasing energy consumption and potentially accelerating cutting edge wear due to excessive cutting forces, ultimately reducing overall cutting efficiency. Therefore, tooth profile design for hard materials should prioritize enhancing cutting edge penetration.
The pitch and tooth depth should be designed to match the toughness of the material, influencing chip evacuation and, consequently, cutting efficiency. Cutting tough materials, such as aluminum and copper alloys, can easily generate long, continuous chips. If the pitch is too small or the tooth depth is insufficient, these chips cannot be evacuated promptly and accumulate in the tooth grooves, causing secondary friction and increasing cutting resistance. In this case, a larger pitch and deeper tooth grooves provide ample space for chips to escape smoothly from the cutting area, reducing frictional losses between the chips and the workpiece and tooth surfaces. For brittle materials, such as cast iron and ceramics, the chips produced during cutting are short and fine. A too small pitch can cause chip blockage. An appropriate pitch design allows these fine chips to be quickly evacuated through the tooth grooves, avoiding interruptions caused by blockage and maintaining stable cutting efficiency. The helix angle design of the tooth profile influences the distribution of cutting forces to adapt to the cutting requirements of different materials. Industrial-use tree-shaped tungsten carbide burrs with helical teeth achieve gradual, rather than instantaneous, contact between the cutting edge and the material during cutting. This design distributes cutting forces and reduces impact. For brittle materials, a smaller helix angle reduces vibration during cutting, preventing material breakage caused by impact and ensuring continuous cutting. For tough materials, a larger helix angle prolongs the contact time between the cutting edge and the material, distributing cutting forces more evenly across the tooth edge, reducing localized wear and promoting helical chip evacuation, thereby improving chip evacuation efficiency. Proper helix angle design enables industrial-use tree-shaped tungsten carbide burrs to maintain a stable cutting rhythm across a wide range of materials, minimizing energy waste.
The symmetry and uniformity of the tooth profile are crucial to efficient cutting of composite materials. Composite materials are often composed of a combination of materials with varying properties, resulting in an uneven internal structure that is prone to force fluctuations during cutting. A symmetrical and evenly distributed tooth profile ensures consistent cutting force distribution across different areas of a composite material for industrial tree-shaped tungsten carbide burrs, preventing a drop in cutting speed due to localized excessive forces. For example, when cutting fiber-reinforced composites, a uniform tooth profile evenly cuts fibers in different directions, reducing variations in cutting resistance caused by fiber pull, resulting in a smoother and more efficient material removal process. Asymmetrical or unevenly distributed tooth profiles, on the other hand, may cause localized overload when cutting composite materials, leading to unstable cutting efficiency.
The tooth tip shape and clearance angle design influence frictional loss during cutting, which in turn affects the cutting efficiency of different materials. The tooth tip is a critical part of the cutting edge, and its shape determines the contact area with the workpiece surface. For soft materials such as plastics and wood, a large tooth tip radius or a small clearance angle can increase the friction area with the workpiece, leading to increased cutting temperatures, softening the material, and adhering to the tooth tip, forming a built-up edge (BUE), which hinders cutting progress. In these cases, a smaller tooth tip radius and a larger clearance angle can reduce contact friction, minimize the likelihood of BUE, and maintain a sharp cutting edge. For hard materials, appropriate tooth tip strength design (such as a slightly larger radius) can enhance the cutting edge's impact resistance, prevent edge chipping, and ensure sustained, efficient cutting by minimizing edge damage.
The overall structural strength of the tooth profile must be aligned with the material's impact characteristics during cutting to ensure long-term stable cutting efficiency. Different materials experience different impacts on the tooth profile during cutting. For example, when cutting castings, sand holes and hard spots may cause transient impacts on the tooth profile. When cutting thin-walled parts, excessive cutting forces must be avoided, potentially causing workpiece deformation. Tooth profile design must provide adequate structural strength, such as thickened tooth roots and optimized transition radiuses, to resist impact loads and reduce the risk of tooth chipping or tooth fracture. Tooth profiles with insufficient structural strength are easily damaged by impact, requiring frequent replacement or resharpening, which in turn reduces overall processing efficiency. Proper strength design enables industrial tree-shaped tungsten carbide burrs to maintain long-term stable cutting performance in complex materials, ultimately improving overall processing efficiency.
