Peripheral Milling Cutter Assembly for Stable Deep-Cut Machining
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Solution Overview
Problem
Existing milling tools are not suitable for high-speed and large depth of cut operations, leading to unsatisfactory results and vibration issues during machining.
Innovation Solution
A cutting assembly with a tool holder and cutting tools designed for rotational symmetry around a central axis, featuring tool mounting recesses with openings at the front end and interlocking features for precise alignment and clamping, allowing for robust and flexible machining with reduced vibration and improved chip evacuation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional milling tools with centrally mounted inserts are used, then the tool structure is simple and easy to manufacture, but the tool produces vibration and chatter during high-speed and large depth of cut operations
Solution Approach 1:
The tool holder is segmented into multiple functional zones: a central mounting region and multiple peripheral tool mounting recesses distributed around the circumference. This segmentation allows cutting tools to be positioned at optimal radial distances from the rotation axis, improving stability during high-speed and large depth of cut operations while maintaining a manageable structural complexity
Solution Approach 2:
The invention transitions from traditional central mounting (one-dimensional arrangement along the axis) to a multi-dimensional peripheral arrangement where tools are mounted at various radial distances and angular positions around the tool holder circumference. This dimensional change enables better vibration control and chip evacuation while maintaining structural simplicity through modular recess design
2Manufacturing precision
If multiple cutting tools are mounted in peripheral recesses, then vibration and chatter are reduced with high-quality machined surfaces, but the tool holder design becomes more complex
Solution Approach 1:
The peripheral tool mounting recesses are designed with universal features that can accommodate different types of cutting tools (end mills, face mills, etc.) with varying shank dimensions. Each recess includes a bottom support surface and lateral support surfaces that provide consistent positioning and clamping for diverse tool types, achieving high manufacturing precision without requiring complex specialized fixtures for each tool type
Solution Approach 2:
Each tool mounting recess is designed with localized support features: a bottom support surface for axial positioning and lateral support surfaces for radial positioning. These locally optimized support structures provide precise tool positioning and stable cutting performance while keeping the overall tool holder design modular and manageable
3Productivity
If cutting tools are mounted with openings in the front end surface, then chip evacuation is improved, but the tool holder design becomes more complex
Solution Approach 1:
The tool mounting recesses are designed with openings in the front end surface that extract and expose the cutting tool shanks and portions of the cutting portions. This extraction approach creates natural chip ejection paths through the front end surface openings, improving chip evacuation efficiency while maintaining a relatively simple tool holder structure without requiring additional complex chip removal mechanisms
Data Source
AI summary
A cutting assembly for milling includes at least two milling cutting tools with shanks that are arranged in a rotatable tool holder at a distance from the central axis of the tool holder, such that an operational region of a cutting portion of each cutting tool is primarily facing outwards, in a radial direction, from the tool holder central axis.