Double-Sided Rhomboid Turning Insert for Lower Heat and Wear
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Solution Overview
Problem
High-temperature strength alloys used in applications like aircraft engines and land-based turbines are difficult to machine due to increased hardness, stiffness, and heat generation, leading to elevated cutting forces, wear, and rapid tool degradation from abrasive carbide precipitates and low thermal conductivity.
Innovation Solution
A nonsquare rhomboid-shaped double-sided turning insert with a unique cutting geometry, including angled primary and secondary cutting edges, a chip-deflecting surface, and specific flanking angles to manage chip thickness and heat extraction, reducing heat concentration and crack formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If conventional cutting geometry is used on HRSA materials, then cutting forces increase, but tool wear and heat concentration worsen
Solution Approach 1:
The cutting insert employs an asymmetric geometry configuration where the cutting edge is positioned at an angle to the workpiece rotational axis, creating unequal chip thickness distribution across the cutting width. This asymmetric approach allows optimization of cutting forces while managing heat generation and tool wear simultaneously
Solution Approach 2:
The invention changes the geometric parameters of the cutting insert, specifically the angle between the primary cutting edge and the workpiece rotational axis, and the configuration of the cutting geometry surface. These parameter changes enable control over chip thickness and heat extraction efficiency, resolving the contradiction between cutting forces and tool wear
2Productivity
If high cutting speeds are used to improve productivity, then heat generation increases, leading to rapid tool degradation
Solution Approach 1:
The invention introduces a new geometric dimension by angling the primary cutting edge relative to the workpiece rotational axis rather than having it parallel. This dimensional change enables the cutting edge to engage the workpiece in a way that distributes heat generation and improves heat extraction, allowing higher cutting speeds without proportional temperature increases
Solution Approach 2:
By changing the angle parameter between the cutting edge and workpiece axis, and optimizing the cutting geometry surface configuration, the invention enables better heat management at higher cutting speeds, resolving the productivity-temperature contradiction
3Productivity
If chip thickness is increased to remove material faster, then cutting forces increase, but heat extraction improves
Solution Approach 1:
The invention creates local variation in chip thickness across the cutting width by positioning the cutting edge at an angle. This local quality approach allows different zones of the cutting edge to handle different chip thicknesses, optimizing both material removal rate and cutting force distribution
Data Source
AI summary
The present disclosure relates to a rhomboid-shaped double-sided turning insert having a convex cutting corner flanked by two flank faces, wherein the insert comprises, on each side: a rhomboid-shaped rake face opposite the face of the opposite side; a lateral cutting corner surface arranged adjoining and between the two flank faces; two flanking edges, each formed between a respective flank face and a rhomboid side of the rake face; a cutting edge formed by a straight primary cutting edge and a straight secondary cutting edge, formed between the lateral cutting corner surface and the rake face, arranged adjoining and between the two flanking edges, wherein the primary cutting edge is longer than the secondary cutting edge; and a chip-deflecting surface which is recessed and arranged inwardly of said cutting edge; wherein a lateral cutting corner surface of the insert, formed by the lateral cutting corner surfaces of a first and a second side, extends between the first side and second side cutting edges, wherein the primary cutting edge and secondary cutting edge are in reversed positions between the first and second sides.