Face milling cutter and method for machining a surface on a workpiece by means of such a face milling cutter
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Solution Overview
Problem
Existing face milling cutters struggle to achieve the desired surface roughness and versatility in machining surfaces for structures like engine blocks, as they often require specific surface patterns and roughness levels, which are difficult to achieve with conventional tools.
Innovation Solution
A face milling cutter design featuring primary cutting inserts, a pattern forming insert with a wave-shaped cutting edge, and a calibrating insert, allowing for adjustable feed rates and surface roughness, enabling the creation of complex surface patterns and improved tool life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional face milling cutters are used to machine surfaces, then the basic flat surface can be formed, but the desired surface roughness and mesh pattern are difficult to achieve
Solution Approach 1:
The cutting tool is divided into functionally distinct segments: primary cutting inserts for material removal and a pattern forming insert for surface texturing. This segmentation allows each component to be optimized for its specific function, achieving precise surface roughness control through the pattern forming insert's wave-shaped cutting edge while maintaining efficient material removal with primary inserts
Solution Approach 2:
The pattern forming insert features a wave-shaped cutting edge with adjustable axial position relative to the primary cutting inserts. This dynamic positioning capability allows optimization of the mesh pattern depth and surface roughness characteristics by adjusting the axial distance between the pattern forming cutting edge and the primary cutting edges, enabling precise control over the final surface topology
2Manufacturing precision
If the axial position of the pattern forming insert is adjusted to control surface roughness, then the mesh pattern quality improves, but the tool setup complexity increases
Solution Approach 1:
The invention transforms the complex multi-parameter setup process into a simplified single-parameter adjustment system. By designing the pattern forming insert with a wave-shaped cutting edge and providing an adjustable axial positioning mechanism, the operator can control surface roughness and mesh pattern quality through a single axial distance parameter rather than multiple independent adjustments, significantly easing the setup process
3Productivity
If conventional cutting tools are used, then the tool structure remains simple, but the feed rate must be limited to achieve desired surface quality
Solution Approach 1:
The pattern forming insert creates the desired mesh pattern and surface roughness characteristics during the primary face milling operation itself, rather than requiring a subsequent separate machining step. This preliminary action integrates surface texturing into the material removal process, allowing high feed rates to be maintained while achieving the desired surface quality in a single pass
Data Source
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AI summary
A face milling cutter (1) comprising a tool body (2) provided with several primary cutting inserts (20a-20g), a pattern forming insert (30) with a pattern forming cutting edge (37) for forming a grooved pattern in a milled flat surface formed on a workpiece by the primary cutting inserts, and a calibrating insert (40) with a calibrating cutting edge (47) for cutting summits in said grooved pattern. The pattern forming cutting edge is wave-shaped as seen from a direction facing a rake face of the pattern forming insert with a periodic wave shape comprising a plurality of wave crests and intermediate wave troughs. The calibrating cutting edge is located axially between the wave crests and wave troughs of the pattern forming cutting edge as seen in a direction from the rear end (2b) of the tool body towards the front end (2a) of the tool body in parallel with the longitudinal axis (4) of the tool body.