Modular Chamfer Mill for Variable Workpiece Thickness
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Solution Overview
Problem
Conventional chamfer mills are not suitable for thin workpieces or those with varying thickness, as they require manual chamfering and have limited thickness capabilities due to fixed chamfer cutter sizes.
Innovation Solution
An assembled chamfer mill with a tool holder, chamfer bits, an extension shaft, and a screw bolt, allowing the extension shaft's length to be adjusted based on workpiece thickness, enabling precise control of the distance between chamfer bits for simultaneous chamfering of edges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional chamfer mill with fixed chamfer cutter size is used, then the structure is simple, but it cannot accommodate workpieces of varying thickness or thin workpieces
Solution Approach 1:
The chamfer mill is divided into modular components: a tool holder, multiple chamfer bits of different sizes, and extension shafts of varying lengths. This segmentation allows selective assembly of appropriate components based on workpiece thickness, providing adaptability without requiring a completely different tool for each thickness range.
Solution Approach 2:
The chamfer mill transitions from a fixed configuration to a dynamic, adjustable configuration. Extension shafts with different lengths can be selected and assembled to change the distance between opposing chamfer bits, enabling the tool to adapt to various workpiece thicknesses dynamically.
2Productivity
If two chamfer cutters are arranged one on top of another with fixed distance, then simultaneous chamfering is achieved, but the chamfer thickness is limited to a fixed size
Solution Approach 1:
The fixed distance between chamfer cutters is replaced with adjustable extension shafts of varying lengths. This allows the distance between opposing chamfer bits to be dynamically adjusted according to workpiece thickness, maintaining simultaneous chamfering capability while providing adaptability to different thickness requirements.
Solution Approach 2:
The tool holder system is designed to accommodate multiple chamfer bits and extension shafts, making it a universal tool that can handle various workpiece thicknesses and chamfering requirements through selective assembly, rather than requiring separate specialized tools for each application.
3Adaptability or versatility
If manual chamfering with a grinder is used for thin workpieces, then the tool can handle thin workpieces, but the process is time-consuming and less precise
Solution Approach 1:
The chamfer mill provides segmented chamfer bits that can be selected based on workpiece thickness. For thin workpieces, appropriately sized chamfer bits with extended reach via extension shafts can be used, enabling machine-based automated chamfering instead of manual grinding, thus improving productivity while maintaining adaptability to thin workpieces.
4Device complexity
If the distance between chamfer bits is fixed, then the tool structure is simple, but it cannot accommodate workpieces with changing thickness
Solution Approach 1:
The tool is segmented into interchangeable components including extension shafts of different lengths. This segmentation maintains relative structural simplicity while enabling adaptability, as the segmented components can be reconfigured based on workpiece thickness requirements without requiring a completely complex adjustable mechanism.
Data Source
AI summary
An assembled chamfer mill comprises a tool holder, an extension shaft, and chamfer bits locked to two ends of the extension shaft. The chamfer bits each have upper blades and lower blades for chamfering the edges of a workpiece simultaneously. The length of a shaft body of the extension shaft may be set in various sizes. Depending on the thickness and shape of the workpiece, the shaft body having an appropriate length is selected, so as to control the distance between the two chamfer bits. Another extension shaft may be provided to connect a further chamber bit for chamfering the edges of the workpiece simultaneously.