Shim-Mounted Cutting Tool Structure for Reduced Insert Displacement
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Solution Overview
Problem
Current cutting tools face challenges in reducing insert displacement during milling processes, which affects the accuracy and efficiency of cutting operations.
Innovation Solution
A cutting tool design incorporating a holder, shim member, and screws that securely fix the shim member within a pocket, allowing for reduced displacement and effective load distribution, thereby minimizing insert movement and enhancing machining accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional cutting tool structure is used, then the device complexity is low, but the insert displacement is large and machining precision deteriorates
Solution Approach 1:
The cutting tool is divided into multiple functional components: holder, shim member, insert, and screws. The shim member is further segmented with multiple holes for load distribution. This segmentation allows each component to perform its specific function optimally, reducing insert displacement while maintaining manageable complexity through modular design.
Solution Approach 2:
The shim member acts as an intermediary element between the holder and the insert. It mediates the load transfer and provides a stable mounting surface for the insert, thereby reducing insert displacement. The intermediary shim member distributes cutting loads through multiple holes, enhancing precision without requiring complete redesign of the entire tool structure.
2Manufacturing precision
If the shim member is securely fixed with screws, then the insert displacement is reduced, but the device complexity increases
Solution Approach 1:
The shim member combines multiple functions into a single component: it provides a mounting surface for the insert, distributes cutting loads through multiple holes, and is secured to the holder with screws. This merging of functions reduces the need for additional complex components while achieving the goal of reducing insert displacement.
Solution Approach 2:
The shim member serves multiple purposes: it acts as a load-distributing plate, a mounting base for the insert, and a structural element that can be secured with screws. This multi-functionality allows the single shim member to address multiple requirements (precision, load distribution, secure fixation) without proportionally increasing device complexity.
3Strength
If the first hole is positioned ahead of the second hole in rotation direction, then the cutting load is dispersed effectively, but the manufacturing complexity increases
Solution Approach 1:
The shim member features local quality variations through strategically positioned holes with different orientations and locations. The first hole (ahead in rotation direction) and second hole (behind in rotation direction) create asymmetric load distribution paths, optimizing strength and load dispersion at specific locations without requiring complex overall manufacturing processes.
Data Source
AI summary
A cutting tool of the present disclosure may include a holder including a pocket, a shim member, a first screw and an insert. The shim member may include a first hole that opens into an outer side surface and an inner side surface. The pocket may include a second hole corresponding to the first hole. The first screw may be inserted into the first hole and the second hole. A first central axis of the first hole may be located ahead of a second central axis of the second hole in a rotation direction.