Segmented Disc Milling Cutter With Cylindrical Self-Centering
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Solution Overview
Problem
Existing disc-shaped milling cutters face challenges in achieving accurate centering and holding, efficient cooling, and manufacturing complexity due to intricate coolant channel designs and thin thickness, which affect milling accuracy and tool lifetime.
Innovation Solution
A milling cutter design comprising two parts, a front end part with a disc-shaped cutter body and a back end part, featuring a primary holding member and secondary holding member that engage to form a secure locking interface, allowing for improved centering and torque transmission without obstructing insert seat manufacturing, and liquid channels extending outwardly for efficient cooling without the need for seals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a disc-shaped cutter body with thin thickness is used, then the milling cutter can achieve compact size and reduced weight, but the manufacturing of coolant channels becomes intricate and manufacturing precision is difficult to maintain
Solution Approach 1:
The milling cutter is divided into two separate parts: a front end part containing the disc-shaped cutter body and a back end part containing the holding members. This segmentation allows the front end part to be manufactured with simplified coolant channels that extend straight through the thin disc body, while the back end part is manufactured separately and assembled afterward, avoiding the complexity of manufacturing intricate channels in a single thin component.
Solution Approach 2:
The solution moves the complex holding and centering functions from the thin disc plane to the axial dimension by adding back end part holding members that extend along the central axis. This dimensional transition allows straight coolant channels to be manufactured in the thin disc without requiring complex in-plane routing, as the holding structure operates in the axial direction.
2Manufacturing precision
If accurate centering and holding of the disc-shaped cutter body is implemented, then milling accuracy is improved, but the device structure becomes more complex
Solution Approach 1:
The centering function is segmented from the disc body and implemented through dedicated holding members with cylindrical abutting surfaces. The front end part has an inner cylindrical surface while the back end part has an outer cylindrical surface, creating a simple concentric centering arrangement that achieves high milling accuracy without complex mechanisms.
Solution Approach 2:
The cylindrical abutting surfaces of the holding members automatically provide centering when the parts are assembled together. The geometry of the concentric cylindrical surfaces self-aligns the front and back end parts, eliminating the need for additional centering mechanisms or complex adjustment systems.
3Duration of action of stationary object
If the disc-shaped cutter body is cooled efficiently, then tool lifetime is extended, but the coolant channel design becomes intricate due to thin thickness
Solution Approach 1:
The cooling system is integrated into the front end part design with straight coolant channels extending from the outer periphery through the disc body to the central axis. This segmented approach allows simple straight channels rather than intricate in-plane routing, achieving efficient cooling of the thin disc body while maintaining manufacturing simplicity.
4Ease of operation
If insert seats extend through the rear side of the disc-shaped cutter body, then cutting insert accessibility is improved, but manufacturing complexity increases
Solution Approach 1:
The insert seats are integrated into the front end part design, allowing cutting inserts to be accessible from the rear side while maintaining simple manufacturing. The segmentation of the cutter into front and back end parts enables the insert seats to be formed in the front end part without requiring complex through-hole machining that would be needed in a single-piece construction.
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 design enhances centering and holding stability, simplifies manufacturing, and ensures efficient cooling and chip evacuation, leading to improved milling accuracy and extended tool lifetime.
Implementation Method 1
the inner cylindrical surface is abutting the outer cylindrical surface in an abutting region axially located at least between the front side and the rear side in order to center the front end part and the back end part to each other
Implementation Method 2
the back end part comprises a secondary holding member engaging the primary holding member when the front end part and the back end part are mounted to each other to form the milling cutter
Implementation Method 3
liquid channels extending outwardly for efficient cooling
Implementation Method 4
the front end part comprising a disc-shaped cutter body having a front side and a rear side and configured to rotate in a rotary direction around a central axis
Data Source
Figure 1a
Figure 1b
Figure 1c
AI summary
A milling cutter (M) comprises a front end part (1) and a back end part (2). The front end part comprises a disc-shaped cutter body (3) having a front side, a rear side, a central axis (X), and a number of insert seats (4b). A primary holding member (6) extends from the rear side. The back end part comprises a secondary holding member (9) engaging the primary holding member (6) when the front and back end parts are mounted to each other. The disc-shaped cutter body comprises a central cylindrical aperture (22) extending coaxially with the central axis and comprising an inner cylindrical surface (22a). An outer cylindrical surface (20a) is provided on a front portion (20) of the secondary holding member. The inner cylindrical surface is abuts the outer cylindrical surface in an abutting region (23) between the front and the rear sides to center the front and back end parts.