Detachable Multi-Tip Milling Cutter for Precise Tip Replacement
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Solution Overview
Problem
Conventional milling cutters require complex and costly adjustments when replacing worn or damaged tips, necessitating a simpler and more economical solution for tip replacement.
Innovation Solution
A milling cutter design featuring a detachable blade part with a plate-shaped blade-body portion and fixed tips, allowing easy replacement and adjustment, and a body with a matching front-end portion for secure attachment, ensuring high accuracy and reduced deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a multiple-blade configuration with increased number of blades is used for high-speed working, then productivity is improved, but device complexity and cost increase
Solution Approach 1:
The milling cutter is divided into two separable parts: a body and a blade part. The blade part containing multiple tips can be independently replaced when worn, while the expensive body is retained. This segmentation allows high-speed multi-blade operation without requiring replacement of the entire complex cutter assembly.
Solution Approach 2:
The tips on the blade part are designed as consumable components that can be worn and replaced economically. The blade part itself serves as an intermediate disposable component that protects the expensive body from wear, allowing high-productivity operation without permanent damage to the main cutter structure.
2Ease of manufacture
If tips are individually fixed and replaced when worn, then cost is reduced, but adjustment complexity increases
Solution Approach 1:
Multiple tips are merged into a single integrated blade part assembly. Instead of replacing and adjusting individual tips separately, the entire blade part with all tips is replaced as one unit, eliminating complex individual adjustment operations while maintaining cost effectiveness.
Solution Approach 2:
The blade part is pre-assembled with all tips positioned and adjusted to correct angles during manufacturing. When replacement is needed, the pre-adjusted blade part is simply attached to the body without requiring field adjustment, eliminating complex adjustment steps during maintenance.
3Manufacturing precision
If the outer diameter of blade-body portion is set equal to or slightly greater than the front-end outer-circumferential portion, then deformation is suppressed and working accuracy is improved, but ease of attachment may be reduced
Solution Approach 1:
The blade part is designed with an asymmetric diameter relationship: the outer diameter is 100/100 to 97/100 of the body's front-end outer-circumferential portion. This slight asymmetry provides interference fit for high precision while maintaining attachment feasibility through the grooved coupling design.
Solution Approach 2:
The grooves on both the blade part and body are positioned at specific locations to provide localized coupling points. This local quality approach allows the diameter relationship to be optimized for precision at the contact surfaces while maintaining overall attachability through the grooved interfaces.
Data Source
AI summary
This milling cutter includes: a blade part 10 having a plurality of tips 12 each having an end cutting edge 121 and a peripheral cutting edge 122, and a blade-body portion 11 which is a plate-shaped body with the plurality of tips 12 fixed to an outer circumference thereof and has a groove 113 in accordance with a position of each tip; and a body 20 being rotatable around a rotational axis and having a front-end portion 21 having a front-end surface to which a rear-end surface of the blade-body portion 11 is fixable detachably and in close contact therewith, and a front-end outer-circumferential portion whose outer diameter is 100/100 to 97/100 using an outer diameter of the blade part 10 as a reference, the front-end outer-circumferential portion having a body-side groove 211 continuous to the groove 113 of the blade-body portion 11 contacted closely.