Formed Rotary Cutting Tool for End-Surface Burr Removal
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Solution Overview
Problem
Conventional methods for removing end-surface burrs from formed grooves require multiple machines and skilled labor, as they necessitate rotating the workpiece or machine spindle 90 degrees, leading to longer working hours and increased skill requirements due to point-by-point measurement and positioning.
Innovation Solution
A method and tool for chamfering that uses a formed rotary cutting tool with a deformed radial shape to remove end-surface burrs by rotating and moving the tool orthogonally to the axial center, aligning with the original cutting tool's movement locus, allowing for uniform chamfering on the same machine without requiring worker skills.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional method is used to remove end-surface burrs, then burr removal can be achieved, but multiple machines are required and working hours increase due to machine switching and measurement positioning
Solution Approach 1:
The invention combines the groove cutting function and burr removal function into a single formed rotary cutting tool. The tool includes cutting portions for groove cutting and chamfering portions for burr removal integrated on the same tool body, allowing both operations to be performed on the same machine without switching tools or machines, thereby reducing working hours and improving productivity
Solution Approach 2:
The formed rotary cutting tool is designed with multi-functionality, serving both as a groove cutting tool and a burr removal tool. By incorporating both cutting portions and chamfering portions on the same tool, it eliminates the need for separate specialized tools and machines, streamlining the manufacturing process and reducing operational time
2Ease of manufacture
If the workpiece or machine spindle is rotated 90 degrees for burr removal, then burr removal can be performed, but the operation becomes complex and requires skilled labor for measurement and positioning
Solution Approach 1:
The invention merges the groove cutting operation and burr removal operation into a single sequential process using the same tool orientation. The cutting portions cut the groove first, then the chamfering portions remove burrs immediately afterward without requiring any rotation of the workpiece or machine spindle, simplifying the operation and reducing the need for skilled measurement and positioning
Solution Approach 2:
Instead of rotating the workpiece or machine spindle to access different surfaces for burr removal, the invention inverts the approach by designing the tool to perform both cutting and chamfering in the same orientation. The chamfering portions are positioned to act on the end surface during the same tool engagement, eliminating the need for complex repositioning operations
3Manufacturing precision
If point-by-point measurement and positioning is performed for burr removal, then precise chamfering can be achieved, but the time required for measurement and positioning increases
Solution Approach 1:
The chamfering portions are pre-configured on the formed rotary cutting tool at specific positions and angles relative to the cutting portions. This preliminary arrangement ensures that when the tool engages the workpiece, the chamfering action automatically occurs at the correct location and orientation without requiring real-time measurement or positioning adjustments during operation
Solution Approach 2:
The formed rotary cutting tool is designed to perform self-positioning and self-alignment during operation. The relative positions of the cutting portions and chamfering portions are fixed, allowing the tool to automatically maintain the correct geometric relationship between groove cutting and burr removal without requiring external measurement systems or skilled operator intervention for positioning
Data Source
AI summary
A method of removing an end-surface burr of a formed groove cut into a workpiece by rotationally driving around an axial center and moving a formed rotary cutting tool relative to the workpiece in a direction orthogonal to the axial center, by using a formed rotary cutting tool for chamfering acquired by deforming a radial shape of the formed rotary cutting tool used in cutting of the formed groove according to a predefined chamfer angle, and by rotationally driving around an axial center and moving the formed rotary cutting tool for chamfering relative to an end surface of the formed groove in a direction perpendicular to the axial center along an axial center movement locus forming the chamfer angle relative to an axial center movement locus of the formed rotary cutting tool in the cutting of the formed groove, chamfering for removing a burr on the end surface is performed.