Integral Orbital End Mill Cutting Head for Precision Small Hole Machining

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Solution Overview

Problem

Existing orbital milling tools face challenges in achieving high precision for small hole machining, tool insert loosening due to vibration, and the need for multiple inserts which complicates machining of small and medium-sized holes.

Innovation Solution

An orbital milling tool with a single, integral cutting head featuring roughing, semi-finishing, and finishing edges, where the cutting portion is spaced apart from the spindle axis, allowing for adjustable orbital movement to accommodate varying hole diameters, and eliminating the need for inserts by integrating all cutting edges into a single unit.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple tool inserts are used for different machining stages, then versatility for rough and finish machining is improved, but device complexity and tool changing time increase

Engineering Contradiction:

Improveversatility for rough and finish machiningVSAvoiddevice complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent combines multiple cutting edges with different functions (roughing, semi-finishing, and finishing edges) into a single integral cutting head. This merging eliminates the need for multiple separate inserts or tool changes, thereby reducing device complexity while maintaining versatility for different machining stages.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The cutting head is designed with multi-functionality by incorporating roughing edges, semi-finishing edges, and finishing edges in a single tool. This allows one tool to perform multiple machining operations (roughing, semi-finishing, and finishing) that would traditionally require multiple separate tools or inserts.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If tool inserts are used for machining, then adaptability for different hole sizes is improved, but reliability decreases due to insert loosening from vibration

Engineering Contradiction:

Improveadaptability for different hole sizesVSAvoidreliability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent merges all cutting edges into a single integral cutting head without separate inserts. This eliminates the loosening problem associated with vibrated inserts while maintaining the ability to machine different hole sizes through orbital movement adjustment.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The cutting head is designed with adjustable orbital movement capability, allowing dynamic adaptation to different hole diameters. The orbital radius can be adjusted to accommodate varying machining requirements, providing adaptability without relying on interchangeable inserts.

Inventive Principle:

Principle #15Dynamics

3Productivity

If orbital milling is used to machine holes larger than end mill diameter, then productivity for large holes is improved, but manufacturing precision for small holes deteriorates

Engineering Contradiction:

Improveproductivity for large hole machiningVSAvoidmanufacturing precision for small hole machining

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The cutting head incorporates adjustable orbital movement with variable orbital radius, enabling dynamic adaptation to different hole sizes. For small holes, the orbital radius can be reduced to maintain precision, while for large holes, the orbital radius can be increased to maintain productivity benefits.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

Different portions of the cutting head have specialized edges optimized for specific functions: roughing edges for material removal, semi-finishing edges for intermediate work, and finishing edges for precision surface work. This local quality optimization ensures precision is maintained even when using orbital milling for productivity.

Inventive Principle:

Principle #3Local quality

4Device complexity

If single integral cutting head is used, then device complexity is reduced, but adaptability for varying hole diameters worsens

Engineering Contradiction:

Improvedevice complexityVSAvoidadaptability for varying hole diameters

Core Design Contradiction:

Device complexityVSAdaptability or versatility

Solution Approach 1:

The cutting head is equipped with adjustable orbital movement capability, allowing the orbital radius to be dynamically changed to accommodate different hole diameters. This dynamic adjustment provides adaptability for varying hole sizes while maintaining the simplicity of a single integral cutting head without multiple inserts.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS8142119B2Method of orbital milling with an orbital end mill, an orbital end mill, and a cutting bit for an orbital end mill

Publication Date: 2012.03.27 KENNAMETAL INC

AI summary

A method of orbital milling is performed using an orbital end mill, which has a cutting bit designed for orbital end milling. The abstract of the disclosure is submitted herewith as required by 37 C.F.R. §1.72(b). As stated in 37 C.F.R. §1.72(b): A brief abstract of the technical disclosure in the specification must commence on a separate sheet, preferably following the claims, under the heading “Abstract of the Disclosure.” The purpose of the abstract is to enable the Patent and Trademark Office and the public generally to determine quickly from a cursory inspection the nature and gist of the technical disclosure. The abstract shall not be used for interpreting the scope of the claims. Therefore, any statements made relating to the abstract are not intended to limit the claims in any manner and should not be interpreted as limiting the claims in any manner.