Segmented Internal Milling Cutter With Axial Clamping Freedom
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing internal milling cutters face challenges in easily exchanging tool holder segments and allowing unrestricted thermal expansion, particularly due to the limitations of dovetailed clamping mechanisms that restrict radial expansion and require complete dismounting for segment replacement.
Innovation Solution
A ring-shaped internal milling cutter design with movably mounted clamps that can transition between locking and releasing positions, allowing axial and radial separation of tool holder segments, enabling easy exchange and thermal expansion without interfering with radial expansion, and featuring a spring-biased mechanism for easy handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a dovetailed clamping mechanism is used to secure tool holder segments, then the segments are firmly held in place, but the mechanism requires complete dismounting for segment replacement and restricts radial thermal expansion
Solution Approach 1:
The clamping mechanism is divided into multiple independent clamps, each capable of securing individual tool holder segments. This segmentation allows each clamp to be operated independently, enabling the release and replacement of single segments without requiring complete dismounting of the entire tool holder assembly, thus resolving the contradiction between secure holding and ease of replacement.
Solution Approach 2:
The clamps are designed with movable elements that can transition between locked and unlocked positions. The dynamic clamping mechanism allows for quick release and repositioning, enabling tool holder segments to be easily removed and replaced while maintaining firm securing during operation, thereby resolving the contradiction between secure holding and ease of operation.
2Reliability
If a dovetailed clamping mechanism is used to secure tool holder segments, then the segments are firmly held in place, but the mechanism restricts free thermal expansion in the radial direction
Solution Approach 1:
The clamping mechanism is divided into multiple independent clamps that apply localized axial clamping forces. This segmentation allows radial gaps to exist between the clamp components and tool holder segments, providing space for radial thermal expansion while maintaining secure axial holding during operation, thus resolving the contradiction between secure holding and thermal expansion freedom.
Solution Approach 2:
The clamping mechanism transitions from radial clamping (which would restrict thermal expansion) to axial clamping. By applying clamping forces in the axial dimension rather than the radial dimension, the mechanism secures tool holder segments firmly while leaving radial space free for thermal expansion, thereby resolving the contradiction between secure holding and thermal expansion adaptability.
3Ease of operation
If the carrier disk mass is reduced by using smaller segments, then handling during insert exchange is easier, but the structural integrity and rigidity may be compromised
Solution Approach 1:
The tool holder segments are segmented into smaller, lighter components that can be easily handled and replaced. The carrier disk maintains its structural integrity through the distributed clamping forces from multiple independent clamps and the optimized ring structure, resolving the contradiction between ease of handling and structural strength.
Solution Approach 2:
The carrier disk and clamping mechanism are designed with localized reinforcement at critical stress points while maintaining lighter construction in non-critical areas. This local quality optimization allows for reduced overall mass and easier handling while preserving structural integrity where required, resolving the contradiction between handling ease and structural strength.
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 design reduces the mass handled during insert exchange, allows simultaneous replacement of cutting edges or inserts, supports thermal expansion, and simplifies the handling and mounting process, enhancing operational efficiency and reducing downtime.
Implementation Method 1
the clamp is located and arranged such that it generates a force in the axial direction pressing the axial contact surface of the tool holder segment onto the axial abutment surface of the carrier disk
Implementation Method 2
the dovetailed clamping piece arranged in a radial direction between the tool holder segment and the main body prevents a free thermal expansion of the tool holder segment in the radial direction
Data Source
AI summary
An internal milling cutter includes a carrier disk having a centre axis defining an axis of rotation of the milling cutter, a plurality of separated tool holder segments removably mounted at the inner circumference of the carrier disk, and at least one clamp for each tool holder segment mounted either on the carrier disk or on the tool holder segment. Each of the tool holder segments at its inner circumference includes at least one cutting insert seat with a mounting element for a cutting insert or at least one cutting edge. The clamp is located and arranged such that it generates a force in the axial direction pressing the axial contact surface of the tool holder segment onto the axial abutment surface of the carrier disk, and the clamp is mounted movably in a radial direction of the carrier disk between a locking position and a releasing position.