End Mill Shank Pre-Machining for Coaxiality
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Solution Overview
Problem
Existing methods for reusing end mills with columnar shank parts require high accuracy machining for new cutting parts, leading to increased workload and limited reuse due to the need for forming new outer peripheral surfaces and ensuring coaxiality, which is inefficient and costly.
Innovation Solution
A reusing method where the end mill's base material is pre-machined to ensure coaxiality accuracy, allowing new cutting parts to be machined on the shank part with a margin of the outer peripheral surface left intact, reducing the need for forming new surfaces and ensuring accuracy, thereby minimizing the workload in machining new cutting parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If the cutting part is repeatedly polished to recover cutting performance, then the end mill can be reused, but the polishing margin is eventually exhausted and polishing reaches its limit
Solution Approach 1:
The invention applies the discarding and recovering principle by cutting off the worn cutting part and recovering the shank part to machine a new cutting part. Instead of repeatedly polishing the same cutting part until the margin is exhausted, the method recovers the base material (shank part) and creates a fresh cutting part, thereby extending the service life beyond what repeated polishing can achieve.
2Manufacturing precision
If a new cutting part is machined from a columnar raw material, then a fresh cutting part is obtained, but high accuracy machining is required to ensure coaxiality and outer peripheral surface accuracy
Solution Approach 1:
The invention applies preliminary action by pre-machining the base material to ensure coaxiality accuracy before the cutting part is worn out. The outer peripheral surface of the shank part is machined in advance with the required precision, so when the cutting part is renewed, the high-precision machining is already completed. This eliminates the need to repeat high-accuracy coaxiality machining for each new cutting part, significantly reducing the machining workload while maintaining manufacturing precision.
3Manufacturing precision
If the outer peripheral surface is machined for each new cutting part, then accuracy is ensured, but the work load increases and efficient reuse is limited
Solution Approach 1:
The outer peripheral surface of the shank part is machined in advance with the required accuracy before the cutting part is worn out. This preliminary machining ensures that when the cutting part is renewed by cutting off the old one and machining a new one, the high-precision outer peripheral surface is already in place. This eliminates the need to repeat the time-consuming high-precision outer peripheral surface machining for each renewal, thereby maintaining manufacturing precision while significantly improving reuse efficiency.
4Manufacturing precision
If high accuracy machining is performed for each new cutting part, then coaxiality is ensured, but the cost and workload increase
Solution Approach 1:
The base material is pre-machined to ensure coaxiality accuracy before the cutting part is worn out. This preliminary high-precision machining is performed only once, and the resulting accurate coaxiality is preserved when the cutting part is renewed. This eliminates the need to repeat high-precision coaxiality machining for each new cutting part, thereby maintaining manufacturing precision while significantly reducing the time and cost associated with repeated high-accuracy machining operations.
Data Source
AI summary
A reusing method of an end mill involves machining a base material of an end mill in advance so as to have coaxiality equal accuracy to coaxiality for a cutting part, and when the cutting part is worn out, cutting off of the cutting part and machining a new cutting part on a shank part while a part of outer peripheral surface of the shank part is left as margin without cutting. The new cutting part has accuracy of coaxiality and an outer diameter identical to those of the cutting part.