Segmented Cutting Tool for Thread Machining
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing material-removing machining tools face challenges in achieving high precision and efficiency, particularly in producing small-scale threads, while also dealing with burr removal and contamination issues, and high production costs.
Innovation Solution
A tool with a specific design featuring cutting elements with defined ratios between the cutting tooth burr and root, and cutting jaw ridge and root, along with a shank for connection to a drive, and integrated cooling channels for efficient machining and heat management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a thread milling cutter with dense teeth is used to machine small-scale threads, then the thread precision is improved, but the chip removal becomes difficult and burr formation increases
Solution Approach 1:
The cutting edge is segmented into multiple discrete cutting teeth with varying tooth heights. The first cutting teeth have a greater height than the second cutting teeth, creating a stepped configuration that segments the cutting action into distinct stages for material removal and finishing, thereby improving chip evacuation while maintaining precision
Solution Approach 2:
Different regions of the cutting edge are given different properties through the varying tooth heights. The first cutting teeth with greater height are optimized for aggressive material removal, while the second cutting teeth with lesser height provide finishing and deburring functions, creating local quality variations that address both precision and productivity requirements
2Productivity
If a thread milling cutter with comprehensive teeth is used to remove material, then the material removal capability is improved, but the deburring becomes insufficient and burrs remain on the thread
Solution Approach 1:
The cutting edge is divided into two functional segments: first cutting teeth for material removal and second cutting teeth for deburring. This segmentation allows each segment to be optimized for its specific function, ensuring both efficient material removal and clean deburring without compromise
Solution Approach 2:
The first cutting teeth perform the preliminary action of material removal to create the thread form, while the second cutting teeth subsequently perform the finishing action of deburring. This sequential preliminary action ensures that burrs are removed after the main cutting operation, achieving both productivity and precision
3Productivity
If the cutting tooth has a large ratio between burr and root, then the material removal is aggressive, but the thread cleanliness is compromised and contamination risk increases
Solution Approach 1:
The cutting edge segments material removal and finishing functions into separate cutting teeth groups. The first cutting teeth with larger burr-to-root ratio aggressively remove material, while the second cutting teeth with smaller burr-to-root ratio clean up burrs, thereby maintaining thread cleanliness and reducing contamination risk while preserving aggressive material removal capability
Solution Approach 2:
Different cutting tooth regions have different burr-to-root ratios optimized for their specific functions. The first cutting teeth have larger ratios for aggressive cutting, while the second cutting teeth have smaller ratios for clean finishing, creating local quality variations that eliminate contamination while maintaining productivity
4Manufacturing precision
If complex processes are used to produce transition radius in the tool, then the machining precision is improved, but the production costs increase significantly
Solution Approach 1:
Instead of using complex processes to create a continuous transition radius, the invention segments the cutting edge into discrete cutting teeth with varying heights. This segmentation achieves the desired machining precision through the stepped tooth configuration, avoiding the need for expensive and complex radius transition processes while maintaining high precision
Solution Approach 2:
The invention uses simple, easily manufacturable cutting teeth with defined height differences rather than complex, expensive tool geometry. The cutting teeth can be manufactured using conventional processes, reducing production costs while achieving the required machining precision through their arranged configuration
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 tool enables precise and efficient material removal with reduced burr formation, improved contamination prevention, and cost-effective production, suitable for small-scale thread machining.
Implementation Method 1
The at least one cooling channel (20) has at least one outlet opening (14) for the coolant in the distal area, in particular in the vicinity of the tool head (3).
Implementation Method 2
The processes are mostly mechanically controlled and driven. In mechanical and manual removal processes, the contact between the tool and the workpiece often generates waste heat due to friction.
Data Source
Figure 1a~1b
Figure 1c
Figure 1d~1e
AI summary
The invention relates to a tool (1) for material removal from a workpiece. The tool (1) has a proximal and a distal end. The tool according to the invention further comprises a shaft (2) for connecting the tool (1) in the region of the proximal end to a drive and a tool head (3) in the region of the distal end. The tool (1) according to the invention further comprises cutting elements (4, 4.1, ..., 4.5, 5.1, ..., 5.3) on the tool head (3), wherein the cutting elements (4, 4.1, ..., 4.5, 5.1, ..., 5.3) are designed such that they are able to penetrate the workpiece to be machined and remove a layer of material from said workpiece. The cutting elements (4, 4.1, ..., 4.5, 5.1, ..., 5.3) further comprise at least one cutting tooth (4, 4.1, ..., 4.5) with a cutting tooth burr (D6, D6.1, ... D6.5) and a cutting tooth root (D7, D7.1, ... D7.5). They further comprise at least one cutting jaw (5, 5.1, ..., 5.5) with a cutting jaw burr (D8, D8.1, ... D8.5) and a cutting jaw root (D9, D9.1, ..., D9.5). In the tool (1) according to the invention, the ratio between the cutting tooth burr (D6, D6.1, ... D6.5) and the cutting tooth root (D7, D7.1, ... D7.5) is smaller than the ratio between the cutting jaw burr (D8, D8.1, ... D8.5) and the cutting jaw root (D9, D9.1, ..., D9.5). In particular, the ratio is between two and ten times smaller.