Replaceable Cutting Ring Milling Tool for Coolant and Chip Control
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Solution Overview
Problem
Conventional milling tools face issues with tool design dependency on machines and tools, leading to suboptimal selection of cutting elements, flute geometry, and coolant delivery, requiring entire tool replacement upon wear and limited adjustability of cutting edges.
Innovation Solution
A modular milling tool design featuring a replaceable ring with cutting elements that can be easily swapped, optimized for cutting materials and flute geometry, with adjustable cutting edges and a 3D-printed coolant distribution system for enhanced chip removal and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cutting elements are firmly soldered on the main body, then the cutting edges remain stable during operation, but the entire main body must be reloaded at the manufacturer when wear occurs
Solution Approach 1:
The tool is divided into a main body and a separate replaceable ring containing the cutting elements. The ring can be removed and replaced independently without affecting the main body, allowing on-site replacement while maintaining cutting edge stability during operation.
Solution Approach 2:
The replaceable ring with worn cutting elements can be discarded or sent for reconditioning separately, while the main body is retained and reused. This eliminates the need to return the entire tool to the manufacturer for reloading.
2Ease of repair
If cartridges are used as replaceable cutting elements, then the cutting elements can be individually replaced, but they must be individually set to a common cutting circle
Solution Approach 1:
Multiple cutting elements are grouped together on a single replaceable ring rather than using individual cartridges. This segmentation allows all cutting elements on the ring to be replaced as one unit, eliminating the need for individual alignment while maintaining ease of replacement.
Solution Approach 2:
Multiple cutting elements are combined on a single ring structure that maintains their relative positions. The ring itself is precision-manufactured to ensure all cutting elements are correctly positioned on the cutting circle, eliminating the need for individual adjustment.
3Reliability
If the tool layout and flute geometry are fixed for specific machines, then the design can be optimized for those machines, but the selection is not optimally selectable for different applications
Solution Approach 1:
The tool design is segmented into a standardized main body and interchangeable rings with different flute geometries and cutting element configurations. This allows the main body to remain optimized for specific machines while the rings can be changed to match different application requirements.
Solution Approach 2:
The standardized main body with universal mounting interface can support multiple types of rings with different flute geometries and cutting element arrangements, allowing a single main body to be used across different machines and applications by simply changing the ring.
4Reliability
If the entire main body is returned to the manufacturer for reconditioning, then all cutting elements can be replaced, but this requires significant time and logistics
Solution Approach 1:
The tool is segmented into a reusable main body and a replaceable ring containing the cutting elements. Only the ring needs to be replaced or reconditioned, not the entire tool, significantly reducing the time and logistics required for maintenance.
Solution Approach 2:
The worn ring can be quickly removed and discarded or sent for reconditioning separately, while the main body is immediately reused. This separates the reconditioning process from the main tool, minimizing tool downtime and logistics complexity.
Data Source
AI summary
An inventive milling tool has a tool head that is rotatable about a tool axis and configured for coupling at its rear to a machine spindle. A plurality of cutting elements are distributed around the tool axis on a cutting circle, each cutting element provided with a front plane cutting edge and a peripheral cutting edge extending at an angle thereto. A channel system extends through the tool head and is configured for delivering coolant to the cutting elements. A replaceable ring is releasably fastened on a front end flange of the tool head in an interlocking manner, and the cutting elements are carried by the replaceable ring.