Cutting Tool Head Member Recesses Suppress Chatter Vibration
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Solution Overview
Problem
Cutting tools with detachable inserts experience chatter vibration and heat radiation issues due to increased protrusion and mass, which affects machining accuracy and efficiency, especially in dry cutting conditions.
Innovation Solution
The head member features recesses on its side surfaces with rib-like protrusions that disperse vibration and reduce weight, allowing for effective heat radiation while maintaining strength through shot peening, with a total recess volume of 2% to 15% of the head member body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the amount of protrusion from the mounting portion to the insert attachment seat is increased, then the cutting blade protrusion is maximized, but chatter vibration is generated and machining accuracy is impaired
Solution Approach 1:
The head member is divided into multiple functional zones: a mounting portion for secure attachment to the holder, a protruding portion with insert attachment seat for holding the cutting insert, and a body portion with optimized geometry. This segmentation allows each zone to be designed independently to optimize its function while minimizing negative effects on other aspects.
Solution Approach 2:
The patent optimizes the three-dimensional geometry of the head member, particularly the protruding portion's shape and dimensions, to achieve the required cutting blade protrusion while maintaining vibrational stability. By carefully controlling the length, width, and height dimensions of the protruding portion, the design maximizes cutting effectiveness without excessive mass that would cause chatter vibration.
2Strength
If the mass of the head member is increased to support larger protrusion, then the structural strength is improved, but vibration attenuation becomes difficult and chatter vibration is more readily caused
Solution Approach 1:
The head member employs local quality optimization by concentrating material where structurally necessary (in the mounting portion and supporting structures) while reducing material in areas where mass would contribute to vibration problems. The protruding portion has optimized wall thickness and internal structure to provide local strength without excessive mass.
Solution Approach 2:
The head member is constructed from cemented carbide, a composite material combining hardness for cutting edge durability with sufficient toughness for structural integrity. This material selection provides the necessary strength-to-weight ratio, ensuring structural strength while minimizing mass that would cause chatter vibration.
3Object-affected harmful factors
If cutting is performed under dry conditions to meet environmental requirements, then environmental impact is reduced, but cutting heat radiation becomes insufficient and thermal damage occurs
Solution Approach 1:
The head member incorporates a porous structure with controlled porosity to increase surface area for heat radiation. The porous geometry allows heat to dissipate more effectively from the cutting insert interface, providing thermal management in dry cutting conditions without requiring additional cooling systems or compromising environmental performance.
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
This design suppresses chatter vibration and enhances heat radiation, ensuring stable and precise cutting operations with reduced thermal damage, even under dry cutting conditions.
Implementation Method 1
the vibration generated as cutting load acting on the cutting insert is dispersed via the rib-like portions and propagates to the holder. As a result, it is possible to suppress chatter vibration of the holder.
Implementation Method 2
the cutting heat generated in the cutting insert can also be rapidly radiated via the head member body.
Implementation Method 3
the strength thereof does not degrade more than needed. Moreover, since the surface area of the head member body is increased by forming the recess, the cutting heat generated in the cutting insert can also be rapidly radiated via the head member body.
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
In a head member (30) for a cutting tool with detachable insert (70) including a head member body (31) formed with an insert attachment seat (36) to which a cutting insert (50) having cutting blades (52) is detachably attached, and constituting the cutting tool with detachable insert (70) by being mounted to a tip portion of a holder (10), a side surface (31A) of the head member body (31) is formed with a recess (44) which has a continuous inner wall surface therearound and a bottom surface connected to the inner wall surface over its whole periphery and which is recessed from the side surface (31A) without passing though the head member body (31). According to this head member (30), generation of chatter vibration can be suppressed even if the amount of protrusion is increased, and the cutting heat of a cutting insert can be efficiently radiated.