Overlay Insert Thread Mill for Single-Pass Rough and Finish Cutting
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Solution Overview
Problem
The machining head replacement type rotary tool has limited usage applications due to its fixed shape, preventing combined machining operations such as simultaneous rough and finish machining.
Innovation Solution
An insert type tool with a cylindrical body and a disc-shaped insert portion, featuring convex and concave portions for attachment and fixation, allowing for configuration by single or multiple inserts coaxially overlaid, enabling combined machining and adjustable pitch through different insert combinations and spacers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a machining head replacement type rotary tool is used, then various machining heads of different shapes can be attached, but the number of machining heads that can be attached is limited to one, preventing combined machining operations
Solution Approach 1:
The tool system is segmented into a holder and multiple detachable machining heads that can be individually attached or combined. The holder includes a attachment face with convex and concave portions that enable modular assembly of one or multiple machining heads, allowing flexible configuration for different machining operations.
Solution Approach 2:
The holder is designed with a universal attachment mechanism that can accommodate various types of machining heads (end mills, face mills, etc.) and configurations (single head, multiple heads). The attachment face with complementary convex and concave portions creates a universal interface that works with different machining head types and arrangements.
2Stability of the object's composition
If the holder shape is fixed, then structural stability is maintained, but usage applications are limited
Solution Approach 1:
The tool system separates the stable holder structure from the variable machining head components. The holder maintains a fixed, stable structure with a standardized attachment face, while the machining heads are detachable segments that can be changed to suit different applications.
Solution Approach 2:
The system introduces dynamic reconfigurability through detachable machining heads that can be attached or removed from the stable holder. The attachment mechanism allows the tool configuration to be dynamically changed while the holder structure remains static and stable.
3Productivity
If multiple inserts are used to enable combined machining, then combined machining capability is achieved, but tool complexity increases
Solution Approach 1:
The machining heads are segmented into modular units that can be independently designed, manufactured, and attached. Each machining head is a discrete component with standardized attachment features, making the system manageable despite having multiple components.
Solution Approach 2:
The universal attachment mechanism simplifies the overall system complexity by providing a standardized interface. The same attachment face design works for all machining head types and configurations, reducing the need for multiple specialized connection mechanisms.
Data Source
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AI summary
An insert portion (3) of a thread mill (1A) is fixed to a leading end portion of a body (2A) using screws (8). The insert portion (3) is configured by overlaying an insert (4) for finish machining and an insert (5) for rough machining. On respective mating faces of the inserts (4, 5), convex portions and concave portions of the mating face of the insert (4) are overlaid with concave portions and convex portions of the mating face of the insert (5). The thread mill (1A) can cut a female screw in a hole formed in a workpiece by performing right-hand cut down-cut milling, for example. The inserts (4, 5) simultaneously cut an inner peripheral surface of the hole, and the rough machining and the finish machining can thus be performed in a single pass. By the convex portions and the concave portions of the respective mating faces of the inserts (4, 5) being overlaid with each other, the inserts (4, 5) partially overlap in their respective thickness directions. As a result, a protrusion length of the insert portion (3) can be shortened.