Multi-Pocket Grooving Holder Structure for Large Blade Projection
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Solution Overview
Problem
Conventional cutting tools with multiple pockets suffer from reduced rigidity as the machining diameter increases, leading to defects in machined surfaces and compromised cutting straightness, particularly in grooving and cutting off machining with large projection amounts.
Innovation Solution
A polygonal plate-like member with insert pockets and recess portions is used in conjunction with a holder that constrains the blade, providing support and reducing deflection through contact with a support portion and a relief portion, enhancing rigidity and machining stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a blade including three or more insert pockets is used to increase economic efficiency, then the number of usable inserts increases, but the rigidity of the tool decreases
Solution Approach 1:
The blade is divided into multiple insert pockets (three or more) arranged along the cutting edge, allowing sequential use of different inserts. This segmentation enables the blade to maintain sufficient structural integrity while providing multiple cutting edges for increased productivity.
Solution Approach 2:
The blade thickness is optimized locally - sufficient thickness is maintained in the root and support areas to ensure rigidity, while the cutting edge portion is designed to accommodate multiple insert pockets. This local quality differentiation allows the blade to achieve both high rigidity and multiple insert capability.
2Adaptability or versatility
If the projection amount of the blade increases to accommodate larger machining diameters, then the applicable machining range increases, but the rigidity of the tool decreases
Solution Approach 1:
The blade is designed with an optimized thickness profile along its length, providing sufficient projection amount for large machining diameters while maintaining adequate thickness in critical areas. The dimensional distribution of material is optimized to balance projection capability with rigidity requirements.
Solution Approach 2:
The blade is constructed from high-strength material with optimized mechanical properties, allowing it to achieve both large projection amount and sufficient rigidity. The material composition and heat treatment are designed to provide high strength-to-weight ratio and resistance to deflection.
3Strength
If the blade thickness is increased to improve rigidity, then the rigidity increases, but the ease of installation and constraint in the holder decreases
Solution Approach 1:
The blade thickness is optimized locally - sufficient thickness is maintained in the root and support areas to ensure rigidity, while the insert pocket areas are designed with appropriate clearance and fit characteristics. This local quality differentiation allows the blade to achieve both high rigidity and ease of installation.
Solution Approach 2:
The blade design incorporates standardized dimensions and tolerances that match the holder's constraint features, ensuring easy installation while maintaining rigidity. The interface between blade and holder is designed with precise geometric correspondence to facilitate straightforward mounting.
Data Source
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AI summary
The present disclosure improves the machining conditions and enhances the quality of machined surfaces, particularly in cutting off and grooving machining when the projection amount of a plate-like member is large. A blade, which is a plate-like member (10) having a polygonal shape and used for cutting machining, includes: a plurality of insert pockets (11); and recess portions (12) formed by partial cutting corresponding to insert pockets respectively. A holder (20) includes: a holder main portion (28); and a support portion (22) with which a part of the recess portion formed in the blade contacts. The holder is configured in which the blade can be installed in a state where the part of the recess portion can contact with the support portion.