Exchangeable Cutter Carrier With Coolant Channels and Precise Runout
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Solution Overview
Problem
Existing milling tools for face milling, particularly those with exchangeable cutters, face challenges in maintaining high changeover accuracy and efficiency when replacing worn cutter carriers without readjusting axial and radial runout, and are not designed to handle heavy axial loads effectively.
Innovation Solution
A milling tool with a tool head and exchangeable cutter carrier featuring a thin, lightweight design for reduced material usage, internal coolant channels for efficient cooling, and adjustable mounting screws for precise alignment, allowing for cost-effective production and easy replacement of the cutter carrier without readjusting the milling tool's runout.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If the cutter carrier is made thin with reduced thickness, then material quantity and manufacturing cost are reduced, but structural strength and ability to handle heavy axial loads deteriorate
Solution Approach 1:
The cutter carrier combines a metal base body with plastic elements (retaining rings, sealing elements, and the multi-part coolant distribution plate) to achieve both lightweight construction and sufficient mechanical strength. The composite structure allows the thin cutter carrier to maintain integrity under heavy axial loads while minimizing material usage.
2Loss of time
If the cutter carrier is made exchangeable with quick-release design, then changeover time and effort are reduced, but manufacturing precision and runout accuracy may deteriorate
Solution Approach 1:
The cutter carrier includes pre-integrated centering elements and precision locating features that are manufactured in advance during cutter carrier production. These preliminary precision features ensure that when the cutter carrier is quickly exchanged, it automatically achieves accurate positioning and minimal runout without requiring additional adjustment operations.
3Productivity
If internal coolant channels are integrated into the cutter carrier, then coolant distribution efficiency is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The coolant distribution system is divided into separate functional components: the cutter carrier base body contains simple through-coolant passages, while the separate coolant distribution plate (made in two parts) contains the complex radial distribution channels. This segmentation allows the coolant distribution plate to be manufactured using additive manufacturing for optimized channel geometry, while the cutter carrier can be produced using conventional machining, thereby reducing overall manufacturing complexity.
4Ease of manufacture
If the coolant distribution plate is constructed in multiple parts, then ease of manufacture and cost are improved, but device complexity increases
Solution Approach 1:
The coolant distribution plate is constructed in two separate parts (first and second parts) that are joined together. This segmentation enables the use of different manufacturing processes and materials for each part, simplifies the manufacturing of complex internal coolant channels through additive manufacturing, and reduces overall production cost despite the increased number of components.
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
The solution enables inexpensive, high-accuracy, and low-effort replacement of cutter carriers, maintaining tool performance and reducing manufacturing time, while the thin design and internal coolant channels enhance coolant distribution and reduce material costs.
Implementation Method 1
the coolant distribution plate includes coolant channels in order to conduct coolant flowing in the axial direction in radial directions to the cutter carrier
Implementation Method 2
at least two parts are placed against each other, with intermediate spaces remaining between the two parts, the intermediate spaces forming the coolant channels
Implementation Method 3
the cutter carrier includes coolant grooves on an end face, in particular on a frontal end face, for guiding coolant towards the cutters, wherein the coolant grooves run from an inner side of the cutter carrier, as seen in the radial direction, to an outer side of the cutter carrier
Implementation Method 4
outlet openings of the coolant channels of the coolant distribution plate are aligned with the coolant grooves
Data Source
AI summary
A milling tool includes a tool head and an exchangeable cutter carrier. The tool head can be coupled to a tool holder, and the cutter carrier includes a plurality of cutters distributed around its circumference, each having a front facing face cutter and a peripheral cutter extending at an angle thereto. In this case, the cutter carrier, including the cutters, has a thickness of at most ten mm, in particular at most six mm, for a diameter of at least fifty mm.