Milling Tool Auxiliary Cutting Edge for Ramping Protection
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Solution Overview
Problem
Milling tools with shim plates face damage during insert breakdowns and back-cutting issues, particularly during ramping operations, which can lead to costly damage to the basic body and unused cutting edges.
Innovation Solution
The shim plate is designed with an auxiliary cutting edge that projects laterally from the inactive cutting edge, featuring a positive cutting geometry and a crescent-like contour, providing protection and guiding away chips to prevent damage during ramping and indexing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a shim plate is used to protect against insert breakdown damage, then the basic body is protected from damage, but the inactive cutting edges are still vulnerable to back-cutting during ramping operations
Solution Approach 1:
The shim plate is segmented into two functional parts: the main body that protects against insert breakdown, and an auxiliary cutting edge that specifically protects inactive cutting edges from back-cutting during ramping operations. This segmentation allows each part to address specific harmful factors independently.
Solution Approach 2:
The auxiliary cutting edge on the shim plate performs preliminary cutting action during ramping operations to prevent the inactive cutting edge of the milling insert from contacting and being damaged by the workpiece. This preliminary action eliminates the harmful back-cutting effect before it can occur.
2Object-affected harmful factors
If the auxiliary cutting edge is added to the shim plate, then inactive cutting edges are protected from back-cutting, but the device complexity increases
Solution Approach 1:
The auxiliary cutting edge is merged with the shim plate structure, combining multiple functions (protection against insert breakdown and protection against back-cutting) into a single integrated component. This merging avoids the need for separate protective devices, thereby limiting the increase in device complexity.
Solution Approach 2:
The shim plate is designed with multi-functionality: it serves both as a protective element against insert breakdown and as an active cutting element that prevents back-cutting during ramping operations. This universality reduces the need for additional specialized components.
3Object-affected harmful factors
If the auxiliary cutting edge projects laterally from the inactive cutting edge, then chip guidance and protection are improved, but the manufacturing precision requirements increase
Solution Approach 1:
The auxiliary cutting edge is positioned with specific local quality characteristics: it projects laterally from the inactive cutting edge by a controlled distance and features a specific positive cutting geometry. This localized precision requirement is concentrated in a specific area rather than throughout the entire shim plate, making the manufacturing more manageable.
Solution Approach 2:
The auxiliary cutting edge projects slightly beyond what would be minimally required for protection, ensuring adequate chip guidance and clearance. This partial excessive action provides a safety margin that accommodates normal manufacturing tolerances without compromising the protective function.
Data Source
AI summary
A milling tool is equipped with milling inserts, below which there are disposed shim plates, the primary function of which is to protect the basic body of the tool in the event of insert breakdowns. The shim plate is formed with a protuberance, in which an auxiliary cutting edge is included, which, in the assembled state of the tool, is located along an inactive cutting edge, which is situated radially inside an active chip removing cutting edge. By means of the auxiliary cutting edge, the milling tool can be utilized for ramping operations without risk of the inactive cutting edge of the milling insert being damaged.