Dual-Insert Turning Tool Layout for Low-Vibration Internal Machining
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Solution Overview
Problem
Existing turning tools face limitations in certain applications, particularly in reducing vibrations during metal cutting operations and require improvements for effective use in internal turning of holes with small diameters and varying profiles.
Innovation Solution
A turning tool design featuring two cutting inserts at the front end, with a roughing insert positioned ahead of a profiling insert, allowing for effective metal removal and surface finishing, and a wide tool body diameter to reduce vibrations and deflection, enabling machining of holes with small entrance diameters and varying depths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single cutting insert is used, then the tool structure is simple, but productivity is reduced due to tool change requirements
Solution Approach 1:
The patent combines two different cutting inserts (roughing insert and profiling insert) on a single tool body, allowing both roughing and profiling operations to be performed without tool changes. This merging of functions directly addresses the productivity loss caused by tool changes while accepting increased structural complexity as a necessary trade-off.
Solution Approach 2:
The tool body is designed to accommodate multiple cutting inserts with different functions (roughing and profiling), making the tool universal for performing multiple machining operations in sequence. This multi-functionality eliminates the need for separate tools for each operation, thereby improving productivity.
2Object-affected harmful factors
If the tool body diameter is increased to reduce vibrations, then vibration reduction is achieved, but the tool length increases
Solution Approach 1:
The patent changes the physical parameters of the tool body, specifically increasing the diameter, to alter the vibrational characteristics and reduce harmful vibrations during machining. This parameter change directly addresses the vibration problem while accepting the consequence of increased tool length.
3Productivity
If a roughing insert is positioned ahead of a profiling insert, then effective metal removal is achieved, but the tool cannot machine holes with small entrance diameters
Solution Approach 1:
The patent inverts the conventional arrangement by positioning the profiling insert ahead of the roughing insert instead of the other way around. This inversion allows the profiling insert to first create a larger entrance diameter in small holes, enabling the subsequent roughing insert to effectively remove material. This resolves the contradiction by reversing the operational sequence.
Data Source
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AI summary
The present invention relates to a turning tool (1) comprising a tool body (2). The tool body (2) includes a front end (4) and an opposite rear end (3), a peripherical surface (9) connecting the front end (4) and the rear end (3), and a longitudinal central axis (A1) extending from the front end (4) to the rear end (3). The turning tool (1) comprises a first cutting insert (100), which is arranged at the front end (4), wherein the first cutting insert (100) is a roughing cutting insert, and wherein the first cutting insert (100) has a first nose cutting edge (105) comprising a first radially distal point (110). The turning tool (1) further comprises a second cutting insert (200), which is arranged at the front end (4), wherein the second cutting insert is a profiling cutting insert, and wherein the second cutting insert (200) has a second nose cutting edge (206) comprising a second radially distal point (210). As seen in the longitudinal direction, the first radially distal point (110) is positioned closer to the front end (4) than the second radially distal point (210).