Disposable Chamfering Blade with Conical Multi-Edge Design
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Solution Overview
Problem
Conventional chamfering cutters made of high-speed steel have high production costs due to costly and time-consuming groove formation, are not suitable for long-term use, and result in material waste when cutting edges break, while disposable blades with single eccentric cutting edges lead to low efficiency and vibration issues.
Innovation Solution
A disposable chamfering blade with a conical cutter head having multiple chip removing grooves, each with a cutting edge, that can be locked to a cutter body, allowing for high-speed operation without eccentric wobbling and enabling rapid replacement when dull or damaged.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional HSS chamfering cutters are used, then the cutting edge can be formed by grinding, but the production cost is high and the cutter must be discarded when the cutting edge breaks
Solution Approach 1:
The cutter is divided into two separable parts: a reusable cutter body and a disposable blade. The blade can be replaced when dull or damaged, while the expensive cutter body remains in service. This segmentation allows the cutting function to be separated from the structural support, enabling cost-effective replacement of only the consumable part.
Solution Approach 2:
The blade is designed as a disposable component made from materials suitable for single-use or limited-use applications. When the blade becomes dull or damaged, it is discarded and replaced with a new one, eliminating the need to discard the entire cutter assembly and reducing overall production costs.
2Ease of manufacture
If a disposable chamfering blade with single eccentric cutting edge is used, then the blade can be replaced when dull, but the blade produces eccentric wobbling or vibration requiring low-speed operation
Solution Approach 1:
The blade design intentionally incorporates asymmetric features including offset cutting edges and uneven chip removal grooves. This asymmetric configuration creates dynamic balance during rotation, counteracting eccentric wobbling and vibration. The asymmetry is carefully engineered to distribute mass and cutting forces in a way that maintains stable operation at higher speeds.
3Device complexity
If a single cutting edge design is used, then the blade structure is simple, but the chip removal rate is low
Solution Approach 1:
The blade is segmented into multiple cutting edges arranged around its periphery, with each edge capable of engaging the workpiece. This segmentation of the cutting function into multiple parallel operations significantly increases the chip removal rate compared to a single cutting edge, while the modular design keeps the overall blade structure relatively simple.
Solution Approach 2:
Multiple cutting edges and chip removal grooves are merged into a single integrated blade component. This combining of multiple cutting functions into one replaceable unit allows all cutting edges to operate simultaneously, dramatically increasing productivity while maintaining simple blade replacement procedures.
4Productivity
If multiple chip removing grooves are provided on the conical periphery, then the chip removal rate increases, but the blade design becomes more complex
Solution Approach 1:
The chip removal grooves are formed on the conical periphery of the blade, utilizing the curved surface geometry to create efficient chip evacuation paths. The conical shape naturally guides chips away from the cutting zone, and the grooves are strategically positioned to maximize chip removal effectiveness while maintaining a relatively simple overall blade design.
Data Source
Figure 1~2
Figure 3
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AI summary
A disposable chamfering blade (10) is provided with a mounting hole (11) through which the disposable chamfering blade (10) can be locked to a cutter body (20). One end of the disposable chamfering blade (10) is provided with a conical cutter head (12) whose conical periphery is circumferentially provided with a plurality of chip removing grooves (13). Each chip removing groove (13) has a side face formed as a cutting edge (14) such that the disposable chamfering blade (10) is formed with a plurality of cutting edges (14) for continuous cutting.