Abstract
Milling cutters belong to a widely used category of cutting tools. In this category, modular milling cutters are a narrow niche, less studied, and developed. Usually, they are symmetrical cutting tools. A milling cutting tool that can be reconfigured due to its modularity and still keeps its symmetry becomes more interesting and useful for machining. The paper presents such a new concept in a computer aided design (CAD) model of a cutting tool based on some novel features. The tool itself is designed as a modular complex. The way the torque is transmitted from the shaft to the elementary cutters is an original one, as they are joined together based on a profiled assembling. The profile is one formed of filleted circular sectors and segments. The reaming of the elementary cutters has two sections each of them assuming a task: transmitting the torque, and precisely centring, respectively. The cooling system, which is a component of the tool, provides the cutting area with coolant both on the front and side face of the cutting tool. Some nozzles placed around the cutting tool send jets or curtains of coolant towards the side surface of the cutter, instead of parallel, as some existing solutions do. The source of the coolant supply is the inner cooling system of the machine tool. This provides the tool with coolant having proper features: high enough flow and pressure. The output of the research is a CAD-based model of the modular milling cutter with a high performance cooling system. All of this model’s elements were designed taking into account the design for manufacturing principles, so it will be possible to easily manufacture this tool. Several variants of milling cutters obtained by reconfiguring the complex tool are presented. Even if the tool is usually a symmetric complex, it can process asymmetric parts. Symmetry is intensively used to add some advantages to the modular cutting tool: balanced forces in the cutting process, the possibility of controlling the direction of the axial cutting force, and a good machinability of the grooves used to assemble the main parts of the cutting tool.
Highlights
Milling cutters are widely used in manufacturing due to their capacity to process a large variety of surface shapes, from very simple ones to freeform shapes
Symmetry is intensively used to add some advantages to the modular cutting tool: balanced forces in the cutting process, the possibility of controlling the direction of the axial cutting force, and a good machinability of the grooves used to assemble the main parts of the cutting tool
A computer aided design (CAD) model of original modular milling cutting tool is presented in this paper
Summary
Milling cutters are widely used in manufacturing due to their capacity to process a large variety of surface shapes, from very simple ones to freeform shapes. When it is necessary to cut a part with a certain profile, a solution is to materialize that profile as a generating curve on the milling cutter This might pose some technological problems, both in manufacturing the cutter and sharpening it. The main drawback of these kinds of tools is that they can be used only for a specific job Because of their narrow range of applications they are available for, the profiled gang, tool designers rarely focus on this category of cutting tools. Some research papers and their findings have been published on the topic in the scientific literature and at conferences. They point to aspects other than those approached in the present paper.
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