One-Piece Whirling Tool for Precise Thread Machining
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Solution Overview
Problem
Existing thread whirling tools face challenges in maintaining high-precision concentricity and changeover accuracy due to multiple joints, which complicates the machining of threads with high geometric accuracy and surface quality requirements, especially for bone screws, and hinder efficient cooling and chip evacuation, leading to suboptimal tool utilization and increased machining time.
Innovation Solution
A one-piece whirling tool with internal cutting teeth and a conical centering mechanism for direct mounting in the drive spindle, featuring a three-point contact interface for secure fastening and radial/axial sealing, enabling precise coaxiality and automatic tool change, improved cooling medium supply, and open chip spaces for efficient chip evacuation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple joints are used to assemble the whirling tool (indexable insert to insert carrier, insert carrier to whirling head, whirling head to hollow shaft spindle), then the tool can be manufactured and assembled with standard processes, but the concentricity and changeover accuracy deteriorate due to cumulative tolerance errors
Solution Approach 1:
The patent merges multiple separate components (insert carrier, whirling head, spindle interface) into a single integrated one-piece tool body. This eliminates the multiple joints and their associated tolerance accumulations, achieving concentricity deviations of no more than 0.003 mm and changeover accuracy of no more than 0.002 mm while maintaining ease of manufacture through monolithic construction.
2Adaptability or versatility
If multiple joints and adapters are used to connect the tool to the drive, then the tool can be attached to different machine configurations, but the device complexity increases and precision deteriorates
Solution Approach 1:
The patent combines the tool body, mounting interface, and drive connection elements into a single one-piece structure, eliminating the need for separate adapters and multiple connection joints. This reduces the number of joints from 4 or more to a single integrated connection interface while maintaining adaptability to standard machine tool spindles.
3Adaptability or versatility
If traditional whirling tools with multiple components are used, then the tool structure can accommodate various cutting inserts and configurations, but the cooling medium supply and chip evacuation efficiency deteriorate due to blocked chip spaces
Solution Approach 1:
The patent integrates the cooling medium supply channels and chip evacuation pathways directly into the one-piece tool body structure, ensuring unobstructed chip spaces that are not blocked by separate components, joints, or insert carriers. This design maintains tool configuration flexibility while dramatically improving chip evacuation efficiency and cooling effectiveness.
Data Source
Figure 1~7b
Figure 5~8
AI summary
A whirling tool (21), in particular for forming a thread, comprises a body with cutting teeth (23; 47, 51) integrally formed thereon. Inaccuracies that arise from the attachment of cutting teeth to the tool are thus avoided.