Additive Cutter Carrier Layout for Large-Bore Rotary Cutting Tools
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Solution Overview
Problem
Existing rotary cutting tools are large, heavy, and complex to manufacture, especially for machining large bores and stepped bores, requiring specialized tools for different geometries, which increases manufacturing costs and complexity.
Innovation Solution
A rotary cutting tool design featuring an additively manufactured cutter carrier that extends radially from the base body, allowing for variable configuration of cutter elements and accommodating different machining operations with a smaller base body, enabling efficient production of various cutting tools from a single base body using additive manufacturing, which reduces manufacturing costs and weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional rotary cutting tools are designed for large bore machining, then the tool diameter increases, but the tool weight and moment of inertia increase significantly
Solution Approach 1:
The cutting tool is divided into a base body and separate cutter element carriers that can be independently attached and detached. Only the necessary cutting elements are present at the cutting location, rather than a solid tool of full diameter, reducing weight while maintaining large cutting diameter capability
Solution Approach 2:
The cutter element carriers extend radially outward from the base body, creating a structure where the effective cutting diameter is larger than the base body diameter. This dimensional arrangement allows the tool to machine large bores without requiring the entire tool body to have large diameter, thus reducing weight and moment of inertia
2Manufacturing precision
If specialized tools are manufactured for different bore geometries, then machining precision improves, but device complexity and manufacturing costs increase
Solution Approach 1:
The tool configuration is made dynamic through the ability to attach and detach different cutter element carriers according to the specific machining requirements. Instead of manufacturing different fixed tools for different geometries, the same base body can be equipped with different carriers as needed, reducing overall device complexity while maintaining precision for various bore geometries
Solution Approach 2:
A single base body is designed to accommodate multiple types of cutter element carriers through standardized attachment interfaces. This universal base body can perform multiple machining operations by simply changing the cutter element carriers, eliminating the need for multiple specialized tools and reducing device complexity
3Stability of the object's composition
If cutter elements are integrated into the base body, then structural stability improves, but adaptability for different machining operations decreases
Solution Approach 1:
The cutting tool is segmented into a stable base body and separate cutter element carriers. The base body maintains structural stability and provides the connection to the machine interface, while the cutter element carriers are detachable components that can be changed according to different machining operations, thus preserving both stability and adaptability
Solution Approach 2:
The cutter element carriers act as intermediary components between the stable base body and the cutting edges. They provide a flexible interface that allows the stable base body to support various different cutting configurations without compromising structural integrity, enabling both stability and versatility
Data Source
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AI summary
A rotating cutting tool (100) is provided, comprising: a base body (10) extending along a longitudinal axis (L) and having a first end (11) for connection to a machine interface and a free second end (12), and at least one additively manufactured cutting element carrier (20) arranged at the second end (12) of the base body (10) such that it extends radially outward from a circumferential segment of the base body (10) with respect to the longitudinal axis (L) as a projection. The cutting element carrier (20) has at least one seat (25) for receiving a cutting edge (50) or a cutting insert (40).