Elastic Sleeve Milling Tool Assembly Vibration Absorption
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Solution Overview
Problem
Existing milling tool assemblies face challenges with tight tolerances requiring additional grinding processes and are prone to vibration and shock-induced fracture due to direct coupling of hard carbide cutters with steel shanks, leading to potential joint slack and early tool failure.
Innovation Solution
A milling tool assembly utilizing a partially elastic energy absorbing joint with an intermediate alignment sleeve between the cutter and shank, providing a minimal interference fit and absorbing vibrations and shocks, thus eliminating the need for tight tolerances and reducing the risk of fracture and joint slack.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If direct coupling of hard carbide cutter to steel shank is used, then structural simplicity is improved, but vibration and shock absorption deteriorates leading to fracture
Solution Approach 1:
A resilient intermediate member is introduced between the carbide cutter and steel shank. This intermediate member acts as a mediator that absorbs vibrations and shocks, preventing direct transmission of harmful forces from the cutting operation to the brittle carbide cutter, thereby reducing fracture risk while maintaining overall structural simplicity.
Solution Approach 2:
The resilient intermediate member provides beforehand cushioning by being pre-installed in the joint structure. It is designed to absorb and dampen vibrations and shocks before they can cause fracture to the carbide cutter, proactively protecting the tool rather than reacting to damage after it occurs.
2Manufacturing precision
If tight tolerances are applied to mating surfaces, then alignment precision is improved, but manufacturing complexity increases due to additional grinding processes
Solution Approach 1:
The invention changes the tolerance parameters of the mating surfaces from tight tolerances (less than 5 micrometers) to loose tolerances. The resilient intermediate member compensates for the increased gap (up to 10 micrometers) that results from loose tolerances, eliminating the need for additional grinding processes while maintaining accurate alignment and concentricity.
Solution Approach 2:
The resilient intermediate member serves as an intermediary that compensates for dimensional variations and gaps caused by loose tolerances. It ensures proper alignment and concentricity between the cutter and shank despite the larger clearance, thereby achieving manufacturing precision without increasing manufacturing complexity.
3Ease of manufacture
If loose tolerances are used to simplify manufacturing, then ease of manufacture is improved, but joint stability deteriorates due to gaps and run-out
Solution Approach 1:
The invention changes the physical state and mechanical properties of the intermediate member to be resilient and elastic. This allows the intermediate member to deform and fill gaps caused by loose tolerances, maintaining joint stability and preventing loosening of the thread coupler during operation, even when manufacturing tolerances are relaxed.
Solution Approach 2:
The resilient intermediate member acts as a mediator that maintains stable contact between the cutter and shank despite gaps created by loose tolerances. It prevents joint slack and run-out by continuously adapting to dimensional variations, thereby ensuring joint stability without requiring tight manufacturing tolerances.
4Device complexity
If threaded coupler alone is used for joining, then device simplicity is improved, but positioning accuracy deteriorates requiring additional alignment features
Solution Approach 1:
The resilient intermediate member serves as an intermediary that provides both alignment and positioning functions in addition to the threaded coupler. It ensures accurate concentricity and axial positioning of the cutter while the threaded coupler provides the joining function, achieving high positioning accuracy without significantly increasing overall device complexity.
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 elastic energy absorbing joint ensures accurate alignment and positioning without tight tolerances, reduces the risk of tool fracture, and maintains proper concentricity and axial positioning, enhancing the durability and reliability of the milling tool assembly.
Implementation Method 1
an at least partially elastic, energy absorbing, intermediate alignment sleeve positioned between the cutter and the shank
Implementation Method 2
an at least partially elastic, energy absorbing, intermediate alignment sleeve positioned between the cutter and the shank
Data Source
AI summary
A milling tool assembly has a replaceable cutter and a reusable shank connected to the cutter with a detachable joint. The joint may be, for example, a threaded connection. An intermediate alignment sleeve made of an elastic or semi-elastic material, is positioned between the cutter and the shank about the axis of rotation of the shank.