Roughing Tool Microtoothing for Faster High-Concentricity Assembly
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Solution Overview
Problem
The manufacturing of roughing tools with multiple delicate cutting edges is time-consuming and challenging due to the complexity of precisely adjusting the axial and radial positions of individual cutting edges to achieve high concentricity and quality in micro-channel structures, especially in non-feeding roughing tools.
Innovation Solution
A method involving thermal machining to introduce microtoothing into cutting element blanks pre-mounted on a rotatable tool base body, allowing for coarse pre-adjustment of cutting elements and subsequent ablative fine adjustment to achieve precise cutting tooth dimensions and alignment, reducing assembly time and improving concentricity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If multiple individual cutting edges are assembled on the tool base body, then the cutting part can cover the entire borehole depth, but the assembly process becomes time-consuming and difficult to achieve high concentricity
Solution Approach 1:
The cutting edges are pre-adjusted to their final positions on the tool base body before being fixed in place. This preliminary positioning action ensures that when the cutting edges are subsequently secured, they are already in the correct concentric arrangement, eliminating the need for time-consuming post-assembly adjustments and ensuring high concentricity is achieved directly during the assembly process
Solution Approach 2:
The invention changes the adjustment parameter from micrometer-level precision requirements to millimeter-level coarse adjustment. By using a preliminary adjustment step that operates at a coarser scale, the assembly process becomes significantly faster and less complex, while the final cutting edge positions are still achieved with the required precision through the subsequent fixing step
2Length of moving object
If multiple individual cutting edges are assembled on the tool base body, then the cutting part can cover the entire borehole depth, but the fine adjustment of axial and radial positions becomes extremely complicated
Solution Approach 1:
The cutting edges are pre-adjusted to their final positions on the tool base body before being fixed in place. This preliminary positioning action ensures that when the cutting edges are subsequently secured, they are already in the correct concentric arrangement, eliminating the need for time-consuming post-assembly adjustments and ensuring high concentricity is achieved directly during the assembly process
Solution Approach 2:
Instead of first assembling the cutting edges loosely and then performing complex fine adjustments, the invention inverts the sequence by first performing the adjustment (preliminarily fixing positions) and then securing the components. This reversal of the traditional assembly sequence simplifies the overall process and reduces adjustment complexity
3Loss of time
If cutting element blanks are pre-mounted and then thermally machined, then assembly time is reduced and concentricity is improved, but an additional thermal machining step is required
Solution Approach 1:
The invention merges the mounting and adjustment operations into a single integrated process. By pre-mounting the cutting element blanks in their final positions and then performing thermal machining to create the microtoothing, the process combines what would traditionally be separate mounting and adjustment steps into one efficient operation sequence, reducing total manufacturing time while maintaining high concentricity
Solution Approach 2:
The invention replaces mechanical adjustment methods with thermal machining. Instead of using mechanical means to precisely position and adjust the cutting edges after mounting, the process uses thermal energy to directly machine the cutting edges to their exact final positions and geometries, eliminating complex mechanical adjustment mechanisms
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 and more accurate manufacturing of roughing tools with higher machining accuracy and ease of assembly, achieving superior concentricity and surface quality for subsequent coatings.
Implementation Method 1
a thermally machining process introduces a microtoothing (a cutting profile) with a plurality of axially spaced cutting teeth into the free edge of the cutting element blank premounted on the tool base body
Data Source
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.