Indexable Tool Head Geometry for Joining and Rabbeting
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Solution Overview
Problem
Current machining tool heads require different designs for joining and rabbeting operations, necessitating retooling and increased investment costs, and existing designs are limited in their ability to create internal corners or prevent edge chipping.
Innovation Solution
A tool head design with indexable inserts having opposing axial angles and corner angles less than 90° minus the axial angle, allowing for a single tool head to perform both joining and rabbeting operations without retooling, and preventing edge chipping by directing reaction forces inward.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a tool head is designed with indexable inserts oriented at axial angles for joining operations, then edge chipping is prevented, but the tool head cannot perform rabbeting operations with internal corners
Solution Approach 1:
The tool head is designed with indexable inserts that have multiple functions: they can perform both joining operations (with opposing axial angles) and rabbeting operations (with at least one insert having a cutting corner at the end face level). This multi-functional design allows a single tool head to replace multiple specialized tool heads, achieving versatility without compromising edge quality through the specific angular configuration of the inserts.
2Manufacturing precision
If different tool heads are used for joining and rabbeting operations, then each operation achieves optimal results, but retooling time and investment costs increase
Solution Approach 1:
The invention creates a universal tool head that can perform both joining and rabbeting operations with a single setup. The indexable inserts are configured with specific angular relationships (opposing axial angles for joining, with at least one insert having a cutting corner at end face level for rabbeting) that enable both operations to achieve optimal results without requiring retooling, thereby eliminating retooling time and reducing investment in multiple specialized tool heads.
3Manufacturing precision
If cutting edges are oriented at axial angles to reduce noise and prevent chatter marks, then surface quality improves, but axial reaction forces cause edge chipping
Solution Approach 1:
The indexable inserts are configured with asymmetric angular relationships: opposing axial angles for joining operations that direct reaction forces inward to prevent edge chipping, and specific corner angles (less than 90° minus the axial angle) for rabbeting operations. This asymmetric configuration allows the tool to achieve both surface quality improvement through axial angle orientation and edge protection through controlled reaction force direction.
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The invention relates to a tool head (2) of a machining tool (1) for machining materials and an associated indexable insert. The tool head comprises a base body (9) and several indexable inserts (10, 11) arranged circumferentially around the base body (9). At least one first indexable insert (10) is positioned on a cylindrical surface (6) of the tool head (2) adjacent to its first end face (7), with at least one second indexable insert (11) arranged on the cylindrical surface (6) at an axial distance therefrom. The first and second indexable inserts (10, 11) have leading cutting edges (12) with opposing axial angles (λ1, λ2). The leading cutting edge (12) and a further cutting edge (13) of the first indexable insert (10) abut each other at a leading cutting corner (15) at a corner angle (δ).A first normal direction (n1) to the leading cutting edge (12) points from the first end face (7) to the opposite second end face (8). The leading cutting edge corner (15) lies at the level of the first end face (7). The magnitude of the corner angle (δ) is less than 90° minus the magnitude of the first axial angle (λ1).