Cutting Tool Inserts for Single-Pass Hub Bore Machining
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Solution Overview
Problem
Current cutting tools for machining aluminum rims require multiple passes to avoid excessive chip formation and cutting forces, leading to potential damage to the workpiece or tool, and are not capable of achieving a high metal removal rate during boring and turning operations.
Innovation Solution
The cutting tool features two identically shaped cutting inserts with specific angular arrangements, allowing for the formation of three distinct chip sections during drilling, enabling a single operation for hub bore machining and optimizing cutting edge utilization through interchangeable inserts with varying radii.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple passes are used for drilling out the hub bore to avoid excessive chip formation and cutting forces, then the risk of damage to workpiece or tool is reduced, but the processing time increases significantly
Solution Approach 1:
The cutting insert is divided into multiple cutting corners (first, second, and third cutting corners) with different active cutting edges positioned at different radial distances from the tool axis. This segmentation allows the chip cross-section to be divided into three different chips during drilling, enabling single-pass drilling out of the hub bore while maintaining reliable chip formation and avoiding excessive cutting forces.
2Productivity
If a single operation is used for drilling out the hub bore to increase productivity, then processing time is reduced, but excessive chip formation and cutting forces occur that can damage the workpiece or tool
Solution Approach 1:
Different cutting corners of the cutting insert have different local qualities in terms of their active cutting edge geometry and radial positioning. The first cutting corner has a first active cutting edge, the second cutting corner has a second active cutting edge at a different radial distance, and the third cutting corner has a third active cutting edge. This local differentiation allows each cutting corner to handle different chip formation requirements, enabling single-pass drilling with controlled chip sections and reduced damage risk.
3Adaptability or versatility
If cutting inserts with different geometries are used for different machining operations, then the functionality for various operations is achieved, but the device complexity increases
Solution Approach 1:
The cutting insert is designed with multiple cutting corners (first, second, and third cutting corners) that can perform different machining operations. The same cutting insert can be used for drilling out the hub bore, turning the contact surface, and other operations by utilizing different active cutting edges. This multi-functionality reduces the need for multiple different cutting inserts and simplifies the overall device complexity while maintaining versatility.
Data Source
Figure 1a~1b
Figure 1c~1d
Figure 2
AI summary
The invention relates to a cutting tool for boring and turning, comprising two identical cutting inserts -2, 2'- with a substantially triangular base shape, which are arranged on a shaft-shaped tool body -1- offset from each other in the radial direction by approximately 180°. The cutting insert -2- is further arranged such that two cutting corners -4- and -5- with different axial and radial positions and special orientations of the cutting edge sections -9- and -11- are located in the active cutting insert. The second cutting insert -2'- is arranged such that it has an active cutting corner -3'- with a special orientation of the cutting edge section -10'- and that, simultaneously, its active cutting corner -3'- lies in the axial direction between the active cutting corners -4- and -5- of the first cutting insert -2-.