Roughing Tool Micro-Toothing for Faster High-Concentricity Assembly
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Solution Overview
Problem
The construction and assembly of roughening tools with multiple delicate cutting edges or cutting strips is time-consuming and complex, particularly for feedless tools, due to the need for precise adjustment of cutting edges to achieve high concentricity and quality micro-groove structures.
Innovation Solution
A method involving a tool base body with axially and radially adjustable cassettes for pre-assembling cutting element blanks, followed by a thermally abrasive process to introduce micro-toothing, allowing for precise adjustment and faster production of cutting tools with high machining accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple individual cutting edges are assembled manually with fine adjustment, then high concentricity and micro-groove quality can be achieved, but the assembly process becomes extremely time-consuming and complex
Solution Approach 1:
The cutting tool is divided into multiple independent cutting elements that can be pre-assembled in a modular fashion. Each cutting element can be independently adjusted and secured in adjustable holders, allowing for systematic rather than purely manual assembly. This segmentation enables parallel preparation of cutting elements before final installation, reducing overall assembly time while maintaining precision through individual adjustment capabilities.
Solution Approach 2:
Cutting elements are pre-assembled and pre-adjusted in their holders before being installed in the final tool configuration. The adjustable holders allow for preliminary radial and axial positioning of cutting edges, so that when the complete tool is assembled, the cutting elements are already close to their final precise positions, requiring minimal final adjustment and significantly reducing assembly time.
2Manufacturing precision
If cutting edges are precisely adjusted in both axial and radial directions, then high-quality micro-groove structure is obtained, but the adjustment process becomes extremely complex and time-consuming
Solution Approach 1:
The holders for cutting elements are designed to be adjustable in both radial and axial directions, providing dynamic positioning capability. This allows cutting edges to be precisely positioned according to specific requirements while maintaining the ability to adjust during assembly. The adjustable nature of the holders simplifies the overall adjustment process compared to fixed-position designs, as corrections can be made easily during assembly rather than requiring complex pre-adjustment mechanisms.
Solution Approach 2:
Traditional complex mechanical adjustment mechanisms are replaced with simpler adjustable holder designs that allow direct radial and axial positioning of cutting elements. The holders can be adjusted using straightforward mechanical means during assembly, eliminating the need for complex pre-adjustment devices or multiple adjustment stages, thereby reducing adjustment complexity while maintaining precision.
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
This method enables faster production of roughening tools with higher concentricity and accuracy, reducing the complexity and time required for assembly while maintaining high-quality micro-groove structures.
Implementation Method 1
a micro-toothing (a cutting profile) with a plurality of axially spaced cutting teeth is introduced into the free edge of the cutting element blank pre-mounted on the tool base body using a thermal machining process
Data Source
Figure 1~2c
Figure 3~5
Figure 6a~6c
AI summary
The invention relates to a method for producing a roughing tool (1), particularly a circular milling tool, comprising the following steps: fitting a lateral surface of a tool base body (10) that can be rotatably driven about an axis of rotation (2) with a number of cutting element blanks (20') that are staggered in the axial and/or peripheral direction, such that a free edge of each cutting element blank (20') protrudes out of the lateral surface in the mounted state; inserting a microtoothing comprising a plurality of axially spaced cutting teeth (21) into the respective free edges of the cutting element blanks (20') by a material removal method, preferably by thermal machining, particularly preferably by eroding, in the premounted state on the tool base body (10). The invention further relates to a roughing tool produced by means of such a method.