Cutting Insert Coupling Structure for Milling Tool Rigidity
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Solution Overview
Problem
Existing milling tool systems face challenges in achieving high accuracy and maximum rigidity, which are crucial for producing high-quality profiles and reducing cycle time, due to limitations in the coupling and positioning of cutting inserts within tool holders.
Innovation Solution
The proposed solution involves a cutting insert with a central body, radially projecting cutting teeth, and a coupling structure featuring a circular cylindrical element with a cylinder abutment surface and radially extending ribs, which allows for precise positioning and torque transmission, reducing the load on the ribs and enabling smaller fixing screws, thereby enhancing system stability and accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional coupling structure with grooves and ribs is used to transmit torque, then torque transmission is achieved, but the load on the ribs increases requiring larger fixing screws and reducing positioning precision
Solution Approach 1:
The coupling structure is segmented into distinct functional zones: the cylinder abutment surface handles axial positioning and torque transmission, while the radially extending ribs provide only radial positioning. This segmentation allows each element to be optimized for its specific function, reducing the load on the ribs and enabling smaller fixing screws.
Solution Approach 2:
The invention introduces a new dimension for torque transmission by using the cylinder abutment surface, which provides a circumferential contact area for torque transmission. This eliminates the need for the ribs to transmit torque, reducing their load and allowing them to focus solely on radial positioning.
2Strength
If larger fixing screws are used to handle higher loads on ribs, then the coupling strength increases, but the system rigidity decreases and positioning accuracy is compromised
Solution Approach 1:
By segmenting the load-bearing functions, the invention allows the cylinder abutment surface to handle axial and torque loads, while the ribs handle only radial positioning. This enables the use of smaller fixing screws that do not compromise coupling strength, as the overall structure is designed to distribute loads efficiently.
Solution Approach 2:
The invention changes the geometric parameters of the coupling structure, specifically the orientation and arrangement of the ribs and the addition of the cylinder abutment surface. This parameter change optimizes the load distribution, allowing for smaller fixing screws while maintaining or improving positioning accuracy.
3Stability of the object's composition
If the coupling structure is designed for high rigidity, then system stability improves, but the complexity of the coupling structure increases
Solution Approach 1:
The cylinder abutment surface serves multiple functions: it provides axial positioning, torque transmission, and radial positioning. This multi-functionality reduces the need for additional complex elements, maintaining system stability while avoiding excessive complexity.
Solution Approach 2:
The coupling structure is segmented into simple, distinct elements (cylinder abutment surface and radially extending ribs) with clearly defined functions. This segmentation simplifies the design and manufacturing while achieving high rigidity and stability through optimized load distribution.
Data Source
AI summary
A cutting insert having a first coupling structure, a tool holder having a complementary second coupling structure with a seat for a milling tool system, and a milling tool system having a cutting insert and a holder are all described. The first coupling structure has a circular cylindrical element with a cylinder abutment surface, the circular cylindrical element projecting axially from a bottom surface of a central body and being arranged concentrically with respect to a central axis, A perpendicular abutment surface is arranged perpendicular to the central axis, and at least two ribs project axially from the bottom surface. Each rib has a contact area with a normal direction at least essentially perpendicular to the central axis for opposing a torque about the central axis.