Shell End Mill Body for Double-Sided Insert Positioning
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Solution Overview
Problem
Shell end mills with complex designs and single-sided cutting inserts are expensive, leading to high machining costs due to the need for multiple cutting inserts and receptacles, which increases tool life but not cost-effectiveness.
Innovation Solution
A tool body design featuring a groove transition between base and contact surfaces to accommodate double-sided cutting inserts, reducing the number of required inserts and incorporating coolant outlet openings for enhanced cutting efficiency and tool life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If single-sided cutting inserts are used, then the tool body requires multiple cutting inserts and receptacles to achieve sufficient tool life, but this increases device complexity and machining costs
Solution Approach 1:
The cutting insert is designed with cutting edges on both sides (adding a dimensional aspect), allowing it to function as a double-sided cutting insert. This enables the same insert to be used for multiple cutting operations by flipping it, thereby reducing the number of inserts needed while maintaining sufficient tool life.
Solution Approach 2:
The double-sided cutting insert serves multiple functions: it can be used for both end milling and shell milling operations, and both sides of the insert can be utilized during its service life. This multi-functionality reduces the total number of inserts required in the tool body.
2Duration of action of moving object
If multiple cutting inserts are used to extend tool life, then tool life is improved, but machining costs increase due to complex tool body design
Solution Approach 1:
By utilizing both sides of the cutting insert (adding a dimensional aspect to the insert design), the effective tool life is doubled without increasing the number of inserts. This reduces the complexity of the tool body design and consequently lowers machining costs.
Solution Approach 2:
Instead of discarding the cutting insert after one side is worn out, the insert is recovered and flipped to use the other side. This extends the usable life of each insert without requiring additional inserts or complex tool body modifications.
3Duration of action of moving object
If double-sided cutting inserts are used, then cost-effectiveness and tool life are doubled, but the groove structure requires precise positioning to protect cutting edges
Solution Approach 1:
The groove structure with recesses automatically positions and protects the cutting edges through its geometry. The recesses are designed to receive and protect the cutting edges when they are not in use, providing self-positioning and protection without requiring additional active control mechanisms.
Solution Approach 2:
The groove acts as an intermediary structure between the cutting insert and the tool body. It provides a controlled environment that guides the cutting insert into the correct position and protects the cutting edges during non-cutting phases, mediating the interaction between the insert and tool body.
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 use of double-sided cutting inserts and coolant outlet openings significantly increases cost-effectiveness and cutting performance by doubling tool life and improving material removal rates while maintaining high cutting quality.
Implementation Method 1
The groove is arranged such that a cutting edge, which lies on the side of the double-sided cutting insert that is not used for the cutting at the time, can be received therein. The cutting edge is arranged on the inside of the groove and does not contact the end faces of the groove and thus not contact the tool body.
Implementation Method 2
Additionally, at least one coolant outlet opening for cooling a cutting process is arranged on the end surface of the tool body. These coolant outlet openings also serve to increase the cutting speed and/or the material removal rate.
Data Source
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AI summary
A tool body for a shell end mill is described with at least one spiral chip guiding groove arranged at the circumference of the tool body for chip dissipation and at least two receptacles for indexable cutting inserts arranged at the chip guiding groove. In this case, the receptacles each comprise a base surface having a bore for receiving an indexable cutting insert fastening screw and at least one first abutment surface adjacent to the base surface. The transition between the base surface and the first contact surface is a groove. In addition, a cutting tool is described with such a tool body, wherein a two-sided indexable cutting insert is attached in each receptacle.