Cutting Tool Rake Face Asymmetry for Surface Roughness
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Solution Overview
Problem
Conventional cutting processes for roughening surfaces, such as those on cylindrical inner walls, result in insufficiently rough finishes due to inadequate chip-flow control and unsuitable cutting edge shapes, leading to incomplete breaking of material and burr formation.
Innovation Solution
A cutting tool configuration with a rake face featuring first and second cutting edges, where the first cutting edge is positioned ahead of the second, providing a feed-direction rake-angle, allowing controlled chip-flow interference to break acute-angle ridges and create a sufficiently rough surface, while preventing incomplete breaking pieces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional cutting tool with standard cutting edge configuration is used, then the cutting process can be performed, but the finished surface is insufficiently rough due to inadequate chip-flow control and unsuitable cutting edge shape
Solution Approach 1:
The cutting edge is divided into multiple segments including a first cutting edge and a second cutting edge positioned at different locations. This segmentation allows each cutting edge to perform specific functions: the first cutting edge creates initial cuts while the second cutting edge breaks the ridges between cuts, collectively achieving adequate surface roughness that a single cutting edge cannot accomplish
Solution Approach 2:
The cutting tool employs an asymmetric rake face configuration where the first and second cutting edges have different rake angles relative to the cutting direction. This asymmetry enables optimized chip flow control for each cutting edge, allowing the first cutting edge to efficiently remove material while the second cutting edge effectively breaks the ridges to create the desired rough surface finish
2Manufacturing precision
If the cutting tool lacks proper chip-flow control, then the cutting process is simpler, but incompletely broken pieces and burrs are produced resulting in insufficient roughness
Solution Approach 1:
The chip flow acts as an intermediary mechanism between the cutting edges and the workpiece surface. By controlling chip flow direction and morphology through the asymmetric rake face configuration, the chips effectively break the ridges between cuts and remove incompletely broken pieces, transforming the cutting process into one that produces adequate surface roughness without burrs
Solution Approach 2:
The invention changes the geometric parameters of the cutting edge configuration, specifically the rake angles of the first and second cutting edges. By optimizing these parameters, the chip flow is controlled to achieve effective ridge breaking while preventing the formation of incompletely broken pieces and burrs, thereby achieving adequate surface roughness
Data Source
AI summary
A cutting edge configuration of a cutting tool for performing a cutting process on a surface (21) of a workpiece (19), the cutting tool including a rake face (3) provided with first and second cutting edges (11, 13), the cutting tool being moved relative to the surface-to-be-cut (21) with the first and second cutting edges (11, 13) cutting thereinto to thereby perform the cutting process, wherein the first cutting edge (11) is positioned ahead of the second cutting edge (13) in a cutting direction (z-direction) of the cutting tool to provide the rake face (3) with a feed-direction (y-direction) rake-angle, and the cutting tool is fed in a direction from a side of the second cutting edge (13) to a side of the first cutting edge (11).