Universal Cutting Tool Holder for Varying Insert Radii
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Solution Overview
Problem
Current cutting tool systems require multiple tool holders to accommodate cutting inserts with varying corner nose radii, leading to increased production costs, resource wastage, and reduced productivity due to the need for frequent tool changes during machining.
Innovation Solution
A cutting tool system with a single tool holder that securely retains a family of generally parallelogram-shaped cutting inserts with differing corner nose radii, utilizing an axial alignment clearance face with a consistent clearance angle and geometry to accommodate inserts of varying radii, allowing for efficient machining without the need for multiple holders.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple tool holders are used to accommodate cutting inserts with varying corner nose radii, then each insert can be securely held, but production costs increase and productivity decreases
Solution Approach 1:
The tool holder is designed with a universal insert pocket geometry that can accommodate cutting inserts with different corner nose radii (from 0.2mm to 6.4mm and larger) within the same family. The pocket features a curved bottom surface and specific face geometries that adapt to various insert sizes, allowing a single tool holder to perform multiple functions with different inserts, thereby eliminating the need for multiple specialized tool holders and improving productivity without compromising secure retention
2Reliability
If multiple tool holders are manufactured and stocked to accommodate different corner nose radii, then each insert type can be properly supported, but resource allocation is diverted and distribution is complicated
Solution Approach 1:
The tool holder design consolidates multiple specialized holders into a single universal model that can accommodate the entire family of cutting inserts with different corner nose radii. The insert pocket geometry includes adaptive features such as curved bottom surfaces and configurable face geometries that provide proper support for various insert types, thereby reducing tool holder inventory complexity and simplifying distribution while maintaining reliable support for each insert type
3Reliability
If conventional tool holders with fixed insert pocket geometries are used, then inserts with specific corner radii can be securely held, but inserts with different radii cannot be accommodated, requiring tool holder changes
Solution Approach 1:
The insert pocket geometry incorporates local variations in the form of configurable face geometries and curved bottom surfaces that can adapt to different insert sizes. The pocket design allows for localized adjustments in the retention mechanism, such as varying the angle and position of pocket faces, while maintaining a consistent overall pocket structure. This enables the same tool holder to provide secure retention for inserts with corner nose radii ranging from 0.2mm to 6.4mm and larger, significantly improving adaptability without sacrificing retention reliability
Data Source
AI summary
An improved design of a cutting insert system includes a plurality of indexable peripheral milling cutting inserts adapted to be mounted on a peripheral milling tool holder. Each of the cutting inserts includes an insert width that is the same for each cutting insert. Each of the cutting inserts also includes a corner nose having a corner nose radius dimension that is different for each cutting insert, and an axial alignment clearance face that defines an equivalent face location and an equivalent clearance angle for each of the plurality of cutting inserts when the insert is detachably mounted on the tool holder.