Ceramic End Milling Cutter Conical Peg Threaded Coupling

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Solution Overview

Problem

Conventional end milling cutters with ceramic cutting heads face challenges in machining heat-resistant superalloys due to high temperatures, limited diameter availability, and vibration issues caused by weak solder connections, which restrict their use in larger diameters and high-force machining operations.

Innovation Solution

The end milling cutter features a conical peg with a male thread in the coupling portion, combined with a ceramic cutting head and a carbide metal or steel shank, providing a robust and precise connection that reduces vibration and allows for diameters up to 32 mm, along with features like a perpendicular contact surface, guide portion, and internal coolant bores for improved stability and machining efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a solder connection is used to join the ceramic cutting head to the shank, then the manufacturing process is simple, but the connection strength is insufficient for large diameter tools and high-force machining operations

Engineering Contradiction:
Improvemanufacturing process simplicityVSAvoidconnection strength
Core Design Contradiction:
Ease of manufactureVSStrength

Solution Approach 1:

The connection interface is segmented into multiple functional zones: a conical peg for alignment and initial contact, threaded portions for mechanical fastening, and a soldering surface for thermal bonding. This segmentation allows each zone to contribute specifically to the overall connection strength while maintaining manufacturing feasibility.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The connection system combines multiple materials and joining methods: the conical peg provides geometric alignment, threads provide mechanical interlocking, and solder provides thermal bonding. This composite approach creates a multi-layered connection that overcomes the limitations of any single joining method.

Inventive Principle:
Principle #40Composite materials

2Area of stationary object

If the cutting head diameter is increased beyond 20 mm, then the tool can handle larger workpieces, but the solder connection becomes insufficient and vibration increases

Engineering Contradiction:
Improvecutting head diameterVSAvoidtool stability
Core Design Contradiction:
Area of stationary objectVSReliability

Solution Approach 1:

The conical peg acts as a counterbalancing element that provides geometric alignment and distributes mechanical loads away from the solder joint. The taper geometry creates a self-centering effect that compensates for the increased leverage forces generated by larger diameter cutting heads.

Inventive Principle:
Principle #8Anti-weight (Counterweight)

Solution Approach 2:

The conical peg with its tapered geometry provides a curved contact surface that distributes contact forces over an area rather than a point. This curved interface improves alignment tolerance and reduces stress concentrations that would otherwise lead to vibration and connection failure in large diameter tools.

Inventive Principle:
Principle #14Spheroidality (Curvature)

3Strength

If a conical peg with male thread is added to the coupling portion, then the connection strength and stability are improved, but the device complexity increases

Engineering Contradiction:
Improveconnection strengthVSAvoidstructural complexity
Core Design Contradiction:
StrengthVSDevice complexity

Solution Approach 1:

Multiple connection functions are merged into a single integrated coupling portion: the conical peg provides alignment and load distribution, the threaded portion provides mechanical fastening, and the soldering surface provides thermal bonding. This merging eliminates the need for separate alignment features, fasteners, and bonding surfaces that would otherwise be required.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The coupling portion is designed as a multi-functional component that performs alignment, mechanical connection, thermal conduction, and vibration damping simultaneously. This universal design approach increases connection strength without adding separate components that would increase overall device complexity.

Inventive Principle:
Principle #6Universality (Multi-functionality)

4Temperature

If ceramic cutting material is used, then heat resistance is improved, but thermal conductivity is reduced leading to higher machining temperatures

Engineering Contradiction:
Improveheat resistanceVSAvoidthermal conductivity
Core Design Contradiction:
TemperatureVSLoss of energy

Solution Approach 1:

The shank acts as an intermediary thermal pathway between the ceramic cutting head and the tool holder. While the ceramic provides heat resistance at the cutting interface, the shank conducts heat away from the cutting zone, compensating for the ceramic's low thermal conductivity and preventing excessive heat accumulation.

Inventive Principle:
Principle #24Intermediary (Mediator)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This configuration enhances the stability and smooth operation of the milling cutter, reducing vibration and extending tool life, while enabling effective machining of larger diameters and high-force operations with reduced wear and increased machining quality.

Implementation Method 1

The butt connection is effected in the state of the art by means of hard solder

Methodology Applied
Scientific EffectSoldering: Soldering

Implementation Method 2

The coupling portion has a conical peg with a male thread

Methodology Applied
Scientific EffectFriction: Friction

Implementation Method 3

conical peg with a male thread in the coupling portion, combined with a ceramic cutting head and a carbide metal or steel shank, providing a robust and precise connection

Methodology Applied
Scientific EffectMechanical Fastener: Mechanical Fastener

Implementation Method 4

internal coolant bores for improved stability and machining efficiency

Methodology Applied
Scientific EffectFluid Flow:

Implementation Method 5

Ceramic cutting materials for their part however have an extremely high heat resistance and can therefore be used at high machining temperatures

Methodology Applied
Scientific EffectThermal resistance:

Implementation Method 6

a ceramic cutting head and a carbide metal or steel shank

Methodology Applied
Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS10124421B2End milling cutter for heat-resistant superalloys
Publication Date: 2018.11.13 WALTER AG
  • US10124421B2 patent drawing
  • US10124421B2 patent drawing
  • US10124421B2 patent drawing

AI summary

An end milling cutter for heat-resistant superalloys (HRSA) has a shank and a cutting head, which have a common rotation axis, the shank having a connection section for connection to the cutting head and a coupling section for connection to a tool holder, the cutting head consisting of a solid ceramic part, which has a rotationally symmetrical envelope and is butt-joined to an end face of the connection section. In order to keep excessive vibrations and thus stresses low in the interface between the cutting head and the connection section of the milling cutter and to create milling cutters that can also cover the diameter range above 12 mm and in particular above 20 mm and up to 32 mm, the coupling section has a conical peg having an external thread.