Milling Head with Curved Blade Elements for Chip Removal
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Solution Overview
Problem
Existing milling technologies are inefficient in removing chips during the machining of plastic profiles, leading to contamination and increased cleaning costs, and are not suitable for simultaneous processing of both sides of plastic profiles, limiting production efficiency and precision in window frame production.
Innovation Solution
A milling head with two parallel milling cutters, each equipped with rotating blade elements that generate an air flow to remove chips, allowing for simultaneous machining of two workpieces and reducing contamination, while the blade carriers with cutting edges on their lateral or end faces enable precise machining and welding surface preparation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional milling cutters are used for machining plastic profiles, then the machining process can be performed, but chip contamination occurs and cleaning is required frequently
Solution Approach 1:
The patent combines two previously separate functions into one milling head: the machining function (cutting edges) and the chip removal function (air flow generation). By integrating the air flow generator with the milling cutters, chips are removed during machining without requiring separate cleaning operations or additional space for chip collection, thus eliminating contamination while maintaining high productivity
Solution Approach 2:
The patent uses pneumatic principles by employing air flow generators that create controlled air currents to transport chips away from the machining area. The air flow is directed through channels to efficiently remove chips from the workpiece surface and surrounding area, solving the contamination problem through fluid dynamics rather than mechanical means
2Manufacturing precision
If one milling cutter processes one workpiece at a time, then precise machining can be achieved, but production efficiency is limited
Solution Approach 1:
The patent divides the milling head into multiple independent milling cutters (at least two), each capable of processing a separate workpiece simultaneously. Each cutter maintains its own cutting edges and air flow generation capability, allowing parallel processing while preserving the precision of individual machining operations. This segmentation enables multiple workpieces to be machined at the same time without compromising accuracy
Solution Approach 2:
Each milling cutter in the multi-cutter head is designed with universal functionality, possessing both cutting capabilities and integrated air flow generation for chip removal. This multi-functionality allows each cutter to independently process workpieces with the same precision and chip control as a single cutter would provide, while the collective system achieves higher productivity through parallel operation
3Reliability
If milling operations are performed separately from welding operations, then chip contamination of welding surfaces is avoided, but production time increases
Solution Approach 1:
The patent implements preliminary chip removal action during the machining process itself. The air flow generators actively remove chips from the workpiece surface and surrounding area while machining is occurring, preparing the surfaces for subsequent welding without requiring separate cleaning steps. This preliminary action ensures welding surfaces are clean and ready for immediate welding operations
Solution Approach 2:
The patent maintains continuous useful action by performing machining and chip removal simultaneously in an integrated system. The air flow generation operates continuously during machining to keep the area clean, allowing the process to transition directly to welding without interruption for separate cleaning operations. This continuity eliminates idle time while maintaining welding quality through persistent chip removal
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution significantly reduces chip contamination, increases production efficiency by 50%, allows for simultaneous processing of both sides of plastic profiles, and enhances machining accuracy, enabling precise welding and reduced bead formation in window frame production.
Implementation Method 1
at least one blade element having a curvature being provided on each of the milling cutters and the blade element rotating when the each milling cutter generates an air flow around its axis of rotation to remove the milling chips that have been removed
Data Source
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AI summary
The invention relates to a milling head (10) comprising two milling cutters (1a, 1b) arranged parallel to each other, wherein the milling cutters (1a, 1b) each comprise at least one axis of rotation (A) and at least one cutting carrier (2) extending radially to the axis of rotation with at least one cutting edge (3). For this purpose, at least one vane element (4) having a curvature (B) is provided on the milling cutters (1a, 1b). When the milling cutter (1a, 1b) rotates about its axis of rotation (A), the vane element (4) generates an airflow for the removal of milled chips.