Segmented Milling Cutter Insert for Simultaneous Rough and Finish Machining
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Solution Overview
Problem
Existing milling cutters and indexable inserts are inefficient in performing both rough and smooth machining operations simultaneously, requiring re-adjustment and separate configurations for different cutting edges.
Innovation Solution
A milling cutter and indexable insert design featuring two partial bodies with a polygonal base, where one partial body has roughing edges and the other has finishing edges, arranged to act simultaneously on a workpiece without re-adjustment, allowing for simultaneous rough and smooth machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single indexable insert is used for both roughing and finishing operations, then productivity is improved by combining operations, but the device complexity increases due to the need for multiple cutting edges with different geometries on the same insert
Solution Approach 1:
The indexable insert is divided into two separate partial bodies (first partial body and second partial body), each with its own cutting edges. This segmentation allows each partial body to be independently designed with optimal geometry for its specific function (roughing or finishing), while still being part of the same insert assembly. The partial bodies are rotated relative to each other to enable simultaneous engagement with the workpiece.
Solution Approach 2:
The patent introduces a rotational dimension by arranging the two partial bodies at different angular positions around the insert center. This dimensional arrangement allows both partial bodies to be simultaneously engaged with the workpiece during rotation, enabling concurrent roughing and finishing operations without interfering with each other.
2Device complexity
If separate indexable inserts are used for roughing and finishing operations, then device complexity is reduced with simpler individual inserts, but productivity decreases due to the need for re-adjustment and separate operations
Solution Approach 1:
The patent merges two separate cutting functions (roughing and finishing) into a single indexable insert by combining two partial bodies with different cutting edges. This allows both roughing and finishing operations to be performed in one clamping operation, eliminating the need to change inserts or re-adjust settings between operations.
Solution Approach 2:
The indexable insert is designed as a multi-functional tool that can perform both roughing and finishing operations simultaneously. The first partial body provides roughing cutting edges while the second partial body provides finishing cutting edges, making the single insert universal for multiple machining functions.
3Productivity
If cutting edges are arranged to act simultaneously on the workpiece, then productivity is improved by performing roughing and finishing in one operation, but the ease of operation decreases due to the need for precise initial positioning without re-adjustment
Solution Approach 1:
The two partial bodies are pre-positioned and fixed at specific angular orientations during insert manufacturing, with their cutting edges already configured to engage the workpiece simultaneously. This preliminary arrangement eliminates the need for complex positioning or adjustment operations by the user, as the simultaneous engagement geometry is built-in from the factory.
Data Source
AI summary
A method of machining a workpiece using a rotary milling cutter is disclosed. The method includes rotating a tool head with a shaft, rough cutting a workpiece with a rough cutting edge of a first partial body to remove a first amount of material from the workpiece, and finish cutting a rough-cut surface of the workpiece with a finishing edge of a second partial body to remove a second amount of material from the workpiece, the second amount of material being smaller than the first amount of material. Both the rough cutting edge of the first partial body and the finishing edge of the second partial body simultaneously engage the workpiece to perform both rough cutting and said finish cutting of the workpiece in a single cutting operation.