Curved Cutting Edge Geometry for Rotational Surface Machining
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Solution Overview
Problem
Existing cutting tools are not effectively suited for machining rotationally symmetrical surfaces of rotating workpieces, leading to surface roughness and increased wear, which reduces tool life and efficiency.
Innovation Solution
A cutting tool with a cutting edge that shifts during machining, featuring a curved shape with a radius of curvature between 100 mm and 500 mm, a length of 12 mm to 50 mm, a wedge angle of 65° to 90°, and made of sintered cubic boron nitride material, along with honed and negative land portions to reduce wear and enhance cutting efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional cutting tool with a straight cutting edge is used, then the structure is simple and easy to manufacture, but the surface roughness increases and the cutting resistance increases
Solution Approach 1:
The cutting edge is designed with a curved shape having a radius of curvature R where 100 mm ≤ R ≤ 500 mm. This curvature allows the cutting point to shift along the arc during machining of rotationally symmetrical surfaces, reducing surface roughness and cutting resistance compared to conventional straight cutting edges.
2Duration of action of stationary object
If a short cutting edge is used, then the tool structure is simple, but the flank face wear increases and tool life decreases
Solution Approach 1:
The cutting edge length L is designed to be 12 mm ≤ L ≤ 50 mm, ensuring that the entire cutting edge can be continuously utilized during machining. This continuous utilization distributes wear across the entire flank face, extending tool life by preventing localized wear concentration that occurs with shorter cutting edges.
3Strength
If a large wedge angle is used, then the cutting edge strength increases and fracture is prevented, but the cutting resistance increases
Solution Approach 1:
The wedge angle is optimized to fall within 65° ≤ wedge angle ≤ 90°. This parameter range provides an optimal balance where the cutting edge has sufficient strength to prevent fracture during machining of hardened materials, while maintaining acceptable cutting resistance levels.
4Force
If a cutting edge with small radius of curvature is used, then the cutting resistance is reduced, but the flank face wear increases
Solution Approach 1:
The radius of curvature R is specifically designed to be within the range 100 mm ≤ R ≤ 500 mm. This parameter optimization achieves a balance where the curved cutting edge reduces cutting resistance and surface roughness through point shifting, while the sufficient radius prevents excessive flank face wear that would occur with smaller radii.
Data Source
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AI summary
A cutting tool according to an aspect of the present invention is a cutting tool for cutting a rotationally symmetrical surface of a rotating workpiece. The cutting includes the step of feeding the cutting tool in a direction inclined with respect to a rotational axis of the rotationally symmetrical surface, while holding the cutting tool in contact with the rotationally symmetrical surface. In the step of feeding the cutting tool, the cutting tool has a point that is in contact with the rotationally symmetrical surface and the point shifts as the cutting tool is fed. The cutting tool includes: a rake face; a flank face; and a cutting edge connecting the rake face and the flank face. The cutting edge as seen from above the flank face has a shape including at least one arc, and the arc has a radius of curvature of not less than 100 mm and not more than 500 mm.