Reinforced Milling Tool Structure for Small-Diameter Tool Life
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Solution Overview
Problem
Milling tools with small diameters are prone to deformation due to stress concentration at corner portions and boundary areas of insert seats, leading to reduced tool life.
Innovation Solution
Incorporating a reinforcing wall that covers the cutting insert and extends to intersect with virtual intersection lines, maintaining uniform or increasing web thickness along the tool main body, thereby reducing deformation and elongating tool life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the tool diameter is decreased, then the milling tool can work on smaller components with higher precision, but the web thickness at the rotation axis decreases causing increased deformation and reduced tool life
Solution Approach 1:
The insert seat is divided into multiple regions: a first region with a first web thickness and a second region with a second web thickness. This segmentation allows different portions of the tool main body to have different thickness characteristics, enabling the distal end to maintain sufficient strength while allowing the overall tool diameter to be small for precision work.
Solution Approach 2:
The tool main body is designed with non-uniform web thickness, where the first web thickness at the first region is greater than the second web thickness at the second region. This local quality variation ensures that stress-concentrated areas near the rotation axis have sufficient thickness to prevent deformation, while other areas can be thinner to maintain small overall tool diameter.
2Ease of operation
If the insert seat corner portions are designed to accommodate the cutting insert, then the cutting insert can be properly secured, but stress concentration occurs at the corner portions leading to deformation
Solution Approach 1:
The insert seat is designed with different web thicknesses in different regions. The first region, which includes the corner portions that contact the cutting insert, has a greater web thickness to resist stress concentration and prevent deformation at these critical fixation points.
3Duration of action of stationary object
If the web thickness is increased at the distal end to prevent deformation, then the tool life is extended, but the tool diameter increases reducing precision working capability
Solution Approach 1:
The tool main body is segmented into regions with different web thicknesses. Only the first region near the rotation axis has increased web thickness to prevent deformation, while the overall tool diameter remains small. This selective thickening extends tool life without compromising precision working capability.
Data Source
AI summary
Provided is a milling tool that allows a life of a tool main body to be elongated. The milling tool includes a replaceable cutting insert and a tool main body in which at least one insert seat that fixes the cutting insert is provided on a distal end side. The tool main body has a reinforcing wall covering at least a portion of the cutting insert when the cutting insert that is in a state of being fixed to the tool main body is viewed from the distal end side.