Thread Milling Cutter Single Tooth Insert Design
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Solution Overview
Problem
Existing thread milling cutters face challenges in efficiently cutting long or deep threads due to high cutting forces and vibrations caused by multiple cutting teeth in contact with the workpiece.
Innovation Solution
A cutting insert with a single elongated bar-shaped body featuring a single cutting tooth protruding from the front face, designed to minimize contact area and reduce vibrations by ensuring only one cutting edge is in contact with the workpiece at a time, and a tool holder with slot-like recesses for secure mounting of these inserts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple cutting teeth are used in the cutting insert, then the thread can be cut faster with more cutting edges, but cutting forces increase and vibrations occur when cutting deep threads
Solution Approach 1:
The cutting insert is segmented to have multiple cutting teeth distributed along its length, but only one cutting tooth is active at any given moment during the threading operation. This segmentation allows the tool to maintain high productivity through multiple cutting edges while reducing cutting forces by ensuring single-point contact with the workpiece at any instant.
2Productivity
If multiple cutting teeth are used in the cutting insert, then thread profiling is more efficient, but the risk of vibrations increases during deep thread cutting
Solution Approach 1:
The cutting insert features multiple cutting teeth segmented along its length, but the tool holder and indexing mechanism ensure that only one cutting tooth engages the workpiece at a time. This segmentation strategy maintains milling efficiency through multiple cutting edges while eliminating vibrations by preventing simultaneous contact of multiple teeth with the workpiece.
3Force
If a single cutting tooth is used in the cutting insert, then cutting forces are reduced and vibrations are minimized, but the number of loops required to cut deep threads increases
Solution Approach 1:
The cutting insert is designed with multiple cutting teeth positioned at different axial locations, and the tool holder incorporates an indexing mechanism that dynamically shifts which cutting tooth is active during the threading operation. This dynamic configuration allows the system to maintain low cutting forces (single tooth contact) while reducing the number of loops needed by utilizing multiple cutting edges throughout the insert's length.
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to a cutting insert and a cutting tool, in particular a thread milling cutter, with a cutting insert, wherein the cutting insert has an elongated bar shaped main body with a first end and a second end, and with two side faces and a front face extending between the first end and the second, and wherein the cutting insert (3) has exactly one cutting tooth (35) protruding from the front face (34) which is arranged closer to the first end (31) than to the second end (32) of the cutting insert (3).