Single-Clamp Grinding Rotary Cutting Tools
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Solution Overview
Problem
Conventional methods for manufacturing reamers and drills require two separate machines and clamping operations, leading to inefficiencies such as bending of the workpiece, increased production time, and higher costs due to the need for additional machining steps.
Innovation Solution
A method for grinding rotary cutting tools using a single clamping operation on a single grinding machine, which includes a headstock with a spindle and a guiding support with an incomplete annulus guiding surface. This setup allows for the simultaneous grinding and sharpening of the cutting tool, including the back taper, without the need for multiple machines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional two-step methods are used with separate machines for preparing and sharpening cutting tools, then manufacturing precision can be maintained, but production time increases and productivity decreases
Solution Approach 1:
The patent combines the preparation step (grinding the cutting part from blank bar) and the sharpening step (grinding flutes and cutting edges) into a single integrated process on one grinding machine. The workpiece is clamped once and both operations are performed sequentially without removing the workpiece, thereby increasing productivity while maintaining precision through the same machine tool system.
Solution Approach 2:
The grinding machine is configured to perform multiple functions: it can prepare the cutting part by grinding the blank bar to the desired diameter and length, and subsequently perform sharpening operations by grinding the flutes and cutting edges. This multi-functionality eliminates the need for separate specialized machines and improves production efficiency.
2Productivity
If grinding is performed between centers on a lathe, then the cutting part can be prepared efficiently, but the workpiece is likely to bend and additional center point grinding is required
Solution Approach 1:
The patent extracts the workpiece from the traditional between-centers grinding setup and instead supports it on a dedicated support device during the preparation step. This eliminates the bending issue caused by long workpieces spanning between centers and removes the need for subsequent center point grinding operations, as the support device prevents deformation throughout the process.
Solution Approach 2:
A support device is introduced as an intermediary element between the workpiece and the machine bed. This support device provides stable support during the preparation step, preventing workpiece bending and eliminating the need for additional center point grinding operations that would otherwise be required to correct deformation.
3Manufacturing precision
If multiple clamping operations are performed on separate machines, then each operation can be optimized, but setup complexity and production time increase
Solution Approach 1:
The patent merges multiple clamping operations into a single clamping event. The workpiece is clamped once in the chuck, and both the preparation step (grinding the cutting part) and the sharpening step (grinding flutes and edges) are performed on the same machine without removing or re-clamping the workpiece. This reduces setup complexity and production time while maintaining precision through consistent positioning.
4Loss of substance
If a reinforced shank is used to reduce blank bar diameter, then material removal is reduced, but the workpiece is more prone to bending during grinding
Solution Approach 1:
A support device is introduced as an intermediary element during the preparation step to provide additional support to the workpiece, particularly to the thinner cutting part section. This prevents bending of reinforced shanks with smaller diameter blank bars while allowing the material removal benefits of reinforced shanks to be realized. The support device compensates for the reduced structural rigidity of the thinner workpiece.
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 method significantly reduces production time and costs by eliminating the need for multiple clamping operations and machines, while also improving precision and reducing the likelihood of workpiece bending during the grinding process.
Implementation Method 1
performing sharpening operations, on a portion of the workpiece intended to become to the cutting part of the final cutting tool, with grinding wheels to obtain a sharpening segment and grinding the sharpening segment down to a final diameter
Data Source
Figure 1a~2
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AI summary
The present invention relates to a method for grinding, with a grinding machine (100), a rotary cutting tool (20) comprising a cutting part (22) and a shank (26). The grinding machine (100) comprises a headstock (102) with a spindle (104) arranged to receive one end portion of a workpiece (10) to rotate said workpiece about a rotation axis (X), and a guiding support (50) to support a portion of the workpiece (10) during grinding of the cutting part. The guiding support (50) comprises a guiding surface (52) having a cross-section, within a plane orthogonal to said rotation axis, of an incomplete annulus. The method comprises the following steps: i) mounting said one end portion of the workpiece (10) into the spindle (104) and rotating said workpiece about the rotation axis (X); ii) performing sharpening operations, on a portion of the workpiece intended to become to the cutting part (22) of the final cutting tool with grinding wheels (W2, W3, W4) to obtain a sharpen segment, and iii) grinding the sharpen segment down to a final diameter including the back taper with another wheel (W5) to obtain the cutting part (22) of the cutting tool (20). The portion of the workpiece intended to become to the cutting part (22) of the final cutting tool is supported by the guiding support (50) during steps ii) and iii).