Multi-Edge Milling Tool for Single-Setup Gear Tooth Chamfering
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Solution Overview
Problem
Existing milling tools require repositioning of the workpiece to chamfer flank edges at both end faces, which is time-consuming and inefficient.
Innovation Solution
A milling tool with a cutting insert having two pairs of cutting edges (first and second, and third and fourth) that allow chamfering of flank edges at both end faces without repositioning the workpiece, by rotating the tool in specific directions to maintain cutting forces aligned with the tool's axis of rotation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a conventional milling tool is used to chamfer flank edges at both end faces, then the chamfering operation can be completed, but the workpiece must be repositioned between operations which increases processing time and reduces productivity
Solution Approach 1:
The patent combines two separate chamfering operations into a single operation by equipping the milling tool with multiple cutting edges (first, second, third, and fourth cutting edges) that can simultaneously or sequentially chamfer both end faces of the workpiece without requiring workpiece repositioning, thereby eliminating idle time and improving productivity
Solution Approach 2:
The milling tool is designed with multi-functionality to perform chamfering on both end faces of the workpiece using a single tool configuration. The tool can switch between different cutting edges to accommodate chamfering different flank edges at different end faces, making the tool universal for both operations
2Adaptability or versatility
If the milling tool is moved in different directions to chamfer flank edges, then all flank edges can be accessed, but the cutting forces are not aligned with the tool axis which reduces tool durability
Solution Approach 1:
The patent employs dynamic operation where the workpiece is rotated during the chamfering process. By rotating the workpiece and using multiple cutting edges positioned at different angular locations, the tool can access different flank edges while maintaining the cutting force direction aligned with the tool axis, thus preserving tool durability through dynamic adaptation
Solution Approach 2:
The cutting tool is segmented into multiple cutting edges (first, second, third, fourth cutting edges) that are distributed around the tool periphery. Each cutting edge is responsible for chamfering specific flank edges, allowing the tool to handle different surfaces without changing the fundamental cutting direction, thereby maintaining force alignment and tool reliability
Data Source
Figure 1a~1c
Figure 1d~1e
Figure 1f~2c
AI summary
Milling tool (1) for chamfering flank edges of teeth on a cylindrical toothed workpiece comprising a tool body (2) with a rear part (6) configured for attachment to a machine and a cutting part (10). A cutting insert (20) is mounted to the cutting part and is provided with first and second cutting edges (21, 22) extending in a common extension plane, which is parallel to a longitudinal plane that contains an axis of rotation (3) of the tool body. Said cutting (21, 22) edges are located opposite each other on opposite sides of a radial plane that contains the axis of rotation (3) and is perpendicular to said longitudinal plane, wherein the cutting edges (21, 22) are inclined in relation to this radial plane. The cutting insert has a rake face (25) that faces radially outward away from the axis of rotation (3).