Conical Tool Extension Assembly for Deep-Groove Machining Stability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing machining tool clamping methods, such as collet chucks and thermal shrinking, face issues with tool breakage, vibration, and safety concerns, especially when machining steep surfaces or deep grooves, due to the need for long tools and large tool holding devices that can be hazardous and lead to inaccuracies.
Innovation Solution
A conical force-fitting connection between the machining tool and a tool extension, where the tool extension is designed with a complementary conical receiving region, allowing for secure clamping without thermal shrinking, and made of hard metal to minimize breakage risks, along with a control unit for path- and force-controlled press-fitting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a longer machining tool is used to reach steep surfaces, then the reachability of difficult-to-machine surfaces is improved, but the machining accuracy and stability deteriorate due to increased vibrations
Solution Approach 1:
The tool system is divided into two separate components: a short machining tool for cutting and a long tool extension for reaching. The machining tool is securely clamped to the tool extension, which is then clamped to the tool holder. This segmentation allows the cutting tool to remain short and rigid for accurate machining while the tool extension provides the necessary reach without compromising machining precision.
2Ease of operation
If the tool holding device is made larger to accommodate standard clamping, then the clamping capability is improved, but the risk of collision with workpiece and operator safety deteriorate
Solution Approach 1:
The clamping function is separated from the tool holder by introducing a tool extension component. The tool extension is clamped to the tool holder in a standard manner, and the machining tool is clamped to the tool extension. This segmentation allows the tool holder to maintain its standard size while the tool extension provides the necessary clamping capability without increasing collision risk.
Solution Approach 2:
The tool extension acts as an intermediary component between the tool holder and the machining tool. It receives the clamping force from the tool holder and transmits it to the machining tool, allowing the tool holder to remain compact while still providing secure clamping capability.
3Strength
If thermal shrinking is used to clamp the tool, then the clamping force is improved, but the process complexity and energy consumption deteriorate due to heating requirements
Solution Approach 1:
The clamping system is segmented into mechanical components (tool extension and machining tool with conical connection) rather than relying on thermal shrinking of the entire tool holder. This allows for simplified clamping without heating requirements while maintaining strong clamping force through the conical force-fitting connection.
4Ease of operation
If a slim tool holding device is used to keep the tool shorter, then the reachability is improved, but the structural stability and safety deteriorate at high rotational speeds
Solution Approach 1:
The system is divided into a short machining tool, a slim tool extension, and a standard tool holder. The machining tool remains short for stability, the tool extension provides reachability, and the tool holder maintains structural stability at high speeds. This segmentation allows each component to be optimized for its specific function without compromise.
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 solution enables safe and accurate machining of difficult-to-reach surfaces with shorter, cost-effective tools, reducing the risk of tool breakage and operator safety hazards while maintaining precision and stability at high rotational speeds.
Implementation Method 1
The conical shank region and the conical receiving region are designed complementary to each other with the same cone angle such that, between the conical shank region and the conical receiving region, the machining tool is held in the tool extension exclusively by means of a force-fitting connection
Data Source
AI summary
An arrangement for machining workpieces includes a machining tool (1) having a cutting edge region (3) and a shank (30), the shank (30) having a conical shank region (5) and a receiving region (4) arranged adjacent to the shank region (5), a tool extension (2) having a conical receiving region (21), the conical shank region (5) and the conical receiving region (21) being designed complementary to each other such that the machining tool (1) is held between the conical shank region (5) and the conical receiving region (21) exclusively by means of a force-fitting connection in the tool extension (2), a tool holding device (15) for receiving the tool extension (2). The tool holding device (15) is adapted to be connected to a rotatable spindle of a machine tool. The cutting edge region (3) has a maximum diameter D1 in a plane E perpendicular to a center axis X.