Cutting Tool Control for Swarf Coil Prevention
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Solution Overview
Problem
Conventional turning methods face issues with swarf coils forming and cutting tool abrasion, leading to surface degradation and reduced production efficiency, particularly in automated machining where coils may go unnoticed and tools need frequent replacement.
Innovation Solution
A method involving an electronic control system that alternates the direction of cutting tool passes relative to the workpiece, using two cutting surfaces and controlling feed rates to prevent coil formation, thereby reducing surface abrasion and extending tool life by ensuring even wear and minimizing shock.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional turning methods are used to remove stock from a rotating workpiece, then the cutting process is simple and fast, but the removed stock forms coils of sharp swarf that can scratch and abrade adjacent surfaces of the workpiece
Solution Approach 1:
The patent applies inversion by alternating the direction of tool passes. Instead of continuously moving the tool in one direction along the workpiece axis, the tool is moved in opposite directions (first direction, then second direction) during successive passes. This reversal of motion direction changes the swarf discharge pattern, preventing coil formation and the associated surface abrasion problems while maintaining efficient stock removal.
2Productivity
If cutting tools are used continuously without replacement, then production efficiency is maintained, but the cutting tool becomes abraded and produces less accurate finishes
Solution Approach 1:
The patent implements periodic action by alternating between two cutting surfaces on the tool during successive passes. The first cutting surface is used in one pass direction, then the second cutting surface is used in the opposite pass direction. This periodic alternation distributes wear evenly between two cutting surfaces, extending tool life and maintaining finish accuracy over longer production periods without requiring frequent tool replacements.
3Productivity
If the cutting tool is moved directly into the cut without controlled engagement, then the cutting cycle is faster, but the tool experiences shock and reduced longevity
Solution Approach 1:
The patent applies beforehand cushioning by controlling the tool to follow a curved path during engagement with the workpiece. Instead of moving the tool directly and abruptly into the cut, the curved engagement path gradually introduces the cutting edge into the material, cushioning the initial impact and reducing shock loads on the tool. This protective engagement method extends tool longevity while maintaining cutting cycle efficiency.
Data Source
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AI summary
An electronic control system is programmed to control movement of a cutting tool relative to a rotating workpiece. After engagement of the stock, the tool is controlled to follow a curved path until the cutting surface of the tool reaches a predetermined depth of cut in the stock. The tool is then controlled to follow a straight/linear path, with the cutting surface of the tool engaged with the stock at said predetermined depth of cut. The control system varies the feed rate as the tool rolls into cut along a known path of curvature, to control the thickness of the material which is removed as the tool rolls into cut, e.g. to induce fracture as the material begins to coil. The feed rate as the tool rolls into cut is programmed to vary in relation to an arc of engagement between a cutting surface of the cutting tool and the stock into which the cutting tool is being moved.