Face Milling Cutter With Integrated Burnishing Layout
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Solution Overview
Problem
Existing face milling cutters require separate operations for milling and mechanical surface treatment, increasing production time and cost, especially when dealing with durable and heat-resistant materials like titanium and stainless steel.
Innovation Solution
A face milling cutter design that integrates cutting inserts and burnishing assemblies, allowing simultaneous face milling and mechanical surface treatment by alternately arranging insert seats and burnishing assemblies to quasi-simultaneously smooth and treat the workpiece surface, preventing heat loss and local hardening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate burnishing tool is used after face milling operation, then mechanical surface treatment quality is improved, but production time and production cost increase
Solution Approach 1:
The patent combines the face milling operation and mechanical surface treatment (burnishing) into a single integrated tool. The tool body contains both cutting inserts for face milling and burnishing assemblies with burnishing elements for surface treatment, allowing both operations to be performed simultaneously on the workpiece in one setup, thereby eliminating the need for separate operations and reducing production time
2Manufacturing precision
If burnishing elements are positioned ahead of cutting inserts, then surface treatment is performed in advance, but heat loss occurs and local hardening is caused
Solution Approach 1:
The patent inverts the conventional arrangement by positioning the burnishing assemblies behind the cutting inserts in the direction of rotation. This ensures that the cutting inserts first perform the face milling operation, and then the burnishing assemblies immediately treat the freshly cut surface. This sequencing prevents heat loss and avoids local hardening that would occur if burnishing were performed beforehand on cooler material
3Manufacturing precision
If multiple burnishing assemblies are arranged in the tool body, then surface treatment coverage is improved, but device complexity increases
Solution Approach 1:
The patent divides the surface treatment function into multiple independent burnishing assemblies, each containing a burnishing element that can be independently positioned and adjusted. These segmented assemblies are distributed around the tool body at different angular positions, allowing comprehensive coverage of the workpiece surface while maintaining modular simplicity in each individual assembly unit
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
Achieves excellent surface finishing and stable residual stresses with improved tool life by ensuring quasi-simultaneous mechanical surface treatment, reducing production time and cost.
Implementation Method 1
a spring unit provided in said chamber, wherein the burnishing element against the action of a spring force from the spring unit is moveable inwards in the chamber
Data Source
AI summary
A face milling cutter includes a tool body, at least two cutting inserts for forming a milled flat surface on a workpiece and mounted in a respective insert seat in the tool body, each cutting insert having a secondary cutting edge that constitutes the axially foremost cutting edge of the cutting insert, and several burnishing assemblies with a respective spring-loaded burnishing element arranged in the tool body. The number of the burnishing assemblies in the tool body is the same as the number of insert seats, wherein the insert seats and the burnishing assemblies are alternately arranged in the circumferential direction of the tool body such that each one of the insert seats is followed by an associated one of the burnishing assemblies as seen in the intended direction of rotation of the tool body.