Rotary Cutting Tool Insert Mount for Accurate Centering
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Solution Overview
Problem
Existing rotary cutting tools with separate holder and insert components suffer from alignment inaccuracies due to reliance on male and female thread parts, requiring complex machining and increasing manufacturing costs when the insert is damaged.
Innovation Solution
The rotary cutting tool design features a holder and insert with cone gradient surfaces and through holes, allowing for easy alignment and replacement of the insert without replacing the entire tool, reducing manufacturing costs and machining complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the holder and insert are manufactured as an integrated tool, then the centering accuracy is improved, but the manufacturing cost increases and the entire tool must be replaced when the insert is damaged
Solution Approach 1:
The cutting tool is divided into two separate components: a holder and an insert. The holder contains a recessed part with a cone gradient seat surface, while the insert has a projected part with a matching cone gradient surface. These conical surfaces mate together to provide precise centering and alignment, while allowing the insert to be replaced independently when worn or damaged, avoiding the need to replace the entire tool.
2Ease of repair
If the holder and insert are fixed by screwing male and female thread parts, then the insert can be replaced separately, but the centering accuracy deteriorates due to alignment dependence on thread parts
Solution Approach 1:
The connection mechanism is segmented into two functional elements: the cone gradient surfaces provide precise centering and alignment, while the separate male and female thread parts provide secure fastening. This separation of functions allows the conical surfaces to ensure accurate positioning without relying on the thread parts for alignment, thereby maintaining both centering accuracy and insert replaceability.
Solution Approach 2:
The cone gradient surfaces act as an intermediary element between the holder and insert. They provide a mating interface that ensures precise axial and radial alignment before the thread parts engage to secure the connection. This intermediary conical interface mediates between the positioning requirements and the fastening requirements, achieving both centering accuracy and replaceability.
3Manufacturing precision
If a symmetric mating shape is formed in the holder and insert, then the centering accuracy is improved, but the machining cost increases due to complicated mating shape
Solution Approach 1:
Instead of using a complex symmetric mating shape, the invention employs asymmetric cone gradient surfaces. The holder has a recessed conical surface while the insert has a protruding conical surface with matching gradient. This asymmetric conical interface provides precise centering and alignment functionality while being much simpler to machine than complicated symmetric mating shapes, thereby reducing machining costs while maintaining high centering accuracy.
Data Source
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AI summary
The present disclosure provides a rotary cutting tool having a holder and an insert as separate components, with an improved centering accuracy at a reduced cost. In the rotary cutting tool, the insert includes: a cutting edge that is formed on at least one of one end of the insert and a side surface of the insert; a projected part that is formed on the other end of the insert; and a through hole that extends through the insert along an axial direction of the insert. The projected part has a cone gradient surface such that an outer diameter of the projected part decreases from the one end side of the insert toward the other end side of the insert. The holder has an elongated shape, and the holder is provided with a recessed part on one end where the insert is fixed, wherein the recessed part includes: a recessed housing part in which the projected part is housed, the housing part being provided with a cone gradient seat surface such that an inner diameter increases from the other end side of the holder toward the one end side of the holder; and a female thread part that is located on the other end side of the holder with respect to the housing part, wherein an opening end of the female thread part is connected to the housing part.