Milling Cutter Orientation for Sharp Cutout Corners
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Solution Overview
Problem
Existing methods for milling cutouts with sharp corners require complex machinery and subsequent machining steps like grinding or reaming to achieve sharp edges, which is inefficient and not suitable for use in known machining centers or multispindle automatic milling machines.
Innovation Solution
A method where a milling cutter is oriented in two different orientations to form the corner shape, using both the end face and lateral face to remove material extensively, and by having milling cutters move in opposite directions to create a sharp edge with depthwise overlap, allowing for efficient formation of sharp corners without additional machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a milling cutter with cylindrical surface is used to mill a cutout, then the lateral face can be formed efficiently, but the corner region can only achieve a curved shape corresponding to the cross-sectional curvature, not a sharp corner
Solution Approach 1:
The invention introduces a second orientation for the milling cutter that is angled relative to the first orientation. By milling the corner region in this second orientation, the end face of the milling cutter creates a planar corner surface that intersects with the lateral face at a controlled angle, achieving a sharp corner shape rather than being constrained by the cylindrical cross-section in a single orientation
2Manufacturing precision
If a multi-edged milling cutter is moved in a complex displacement path to form sharp corners, then sharp-edged corners can be achieved, but a relatively complicated machine tool is required
Solution Approach 1:
The invention changes the orientation of the milling cutter dynamically by defining a second orientation that is angled relative to the first orientation. This dynamic reorientation allows the end face to engage with the corner region at an optimal angle, creating sharp corners through a simpler angular positioning approach rather than complex multi-axis displacement paths
Solution Approach 2:
The corner region formation is segmented into two distinct milling operations: first forming the lateral face in the first orientation, then forming the corner shape in the second orientation. This segmentation allows each operation to be optimized independently, with the second orientation specifically targeting corner sharpness using the end face without requiring complex machine tool displacement mechanisms
3Manufacturing precision
If subsequent machining like grinding or reaming is used to achieve sharp corners, then the corner sharpness can be improved, but additional machining steps and time are required
Solution Approach 1:
The invention performs the corner shaping action during the primary milling operation by introducing a second orientation. The end face of the milling cutter is used to create the sharp corner shape directly during material removal, rather than requiring preliminary lateral face formation followed by separate subsequent machining operations like grinding or reaming
Data Source
AI summary
A method for milling a cutout using a milling cutter in a workpiece is provided. A longitudinal axis of the milling cutter is positioned in a first orientation relative to the workpiece to contact a first side of the workpiece. An enveloping cylindrical surface of the milling cutter is then used to cut a cutout which has a plurality of peripheral edges and rounded corners. The milling cutter is then placed in a second orientation which is angled relative to the first orientation. Thereafter, the enveloping cylindrical surface and an enveloping axial surface of the milling cutter are used to further cut the rounded corners of the cutout to form sharp corners.