Resilient Insert Slitting Cutter for Higher Feed and Repeatability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current slitting cutters face limitations in feed rate per revolution, life-cycle, and repeatability due to their design, which restricts their efficiency in slitting operations, especially in materials like spring steel.
Innovation Solution
A disk-shaped slitting cutter with circumferentially spaced insert receiving portions and resiliently clamped cutting inserts, featuring a tool key for stable insertion and extraction, allowing for higher rotational speeds and improved chip evacuation, resulting in increased feed rates and extended tool life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If integral one-piece slitting cutters are used, then the structure is simple and manufacturing is easy, but the feed rate per revolution is limited to approximately 0.02mm and the life-cycle is short
Solution Approach 1:
The cutting tool is divided into a cutter body and separate cutting inserts. The cutting inserts are removable and can be independently replaced or regrinded, allowing for higher feed rates and extended tool life while maintaining manufacturing efficiency through modular construction.
2Device complexity
If integral one-piece slitting cutters are used, then the structure is simple, but the repeatability after regrinding is reduced
Solution Approach 1:
By separating the cutting inserts from the cutter body, the cutting inserts can be precisely reground or replaced without affecting the cutter body geometry. This ensures consistent repeatability while maintaining overall structural simplicity through the modular design.
3Duration of action of moving object
If disk-shaped cutters with removable inserts are used, then the life-cycle is extended, but the device complexity increases with tool keys and insertion mechanisms
Solution Approach 1:
The clamping jaws are designed with resilient elements that provide dynamic clamping force. The resilient clamping mechanism automatically adapts to insert variations and maintains secure holding without complex locking devices, extending tool life while minimizing structural complexity.
4Ease of manufacture
If simple tooth design without chip forming capabilities is used, then the manufacturing is easier, but the feed rate per tooth is limited to approximately 0.4μm due to high cutting forces
Solution Approach 1:
The cutting inserts are equipped with specialized chip forming surfaces and geometries at the cutting edge, while the rest of the insert body maintains simple construction. This localized enhancement of cutting edge quality enables higher feed rates by improving chip evacuation and reducing cutting forces, without complicating the overall insert manufacturing process.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables a feed rate per revolution 10 times greater than traditional slitting cutters, with improved repeatability and extended tool life, enhancing operational efficiency in slitting operations.
Implementation Method 1
the first clamping jaw resiliently displaceable relative to the second clamping jaw and having a resilient axis of rotation, each cutting insert resiliently clamped in its respective insert receiving slot
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A slitting cutter (20) having a disk-shaped cutter body (22) with a plurality of circumferentially spaced insert receiving portions (28) and a plurality of cutting inserts (30) retained therein. Each insert receiving portion has first and second clamping jaws (32, 34) spaced apart by an insert receiving slot (36), the first clamping jaw resiliently displaceable and having a resilient axis of rotation (AR). The number of cutting inserts resiliently clamped in the slitting cutter is an inner cutting diameter (Dl) defined by the plurality of resilient axes of rotation multiplied by a spacing factor of between 0.15 and 0.30. A tool key having first and second key prongs is used in combination with the slitting cutter. The second key prong has a thrust surface with a concave profile. In a partially assembled position of the slitting cutter the thrust surface contacts at least one of two spaced apart first and second corner surfaces of the respective cutting insert.