Multi-Edge Cutting Insert for Power Skiving
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Solution Overview
Problem
Existing power skiving tools require multiple passes to cut complete tooth grooves, resulting in a rough surface that often necessitates additional finishing operations like grinding or fine cutting.
Innovation Solution
A cutting insert with two or three cutting edges, where the first cutting edge provides a deeper cut and the second cutting edge offers a finishing cut, allowing for deeper cutting depths in fewer passes and reducing surface roughness, potentially eliminating the need for subsequent finishing operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a cutting insert with only one cutting edge is used, then the insert structure is simple, but multiple passes are required to cut complete tooth grooves resulting in rough surface finish
Solution Approach 1:
The cutting insert is segmented into multiple cutting edges (first cutting edge and second cutting edge) positioned at different depths. The first cutting edge cuts at a deeper position to remove material, while the second cutting edge cuts at a shallower position to finish the surface, enabling complete tooth groove cutting in fewer passes with improved surface finish
Solution Approach 2:
The invention adds a depth dimension to the cutting edges by positioning them at different distances from the cutting direction. The second cutting edge is positioned closer to the cutting direction than the first cutting edge, creating a multi-level cutting structure that addresses both roughing and finishing in one operation
2Productivity
If multiple passes are used to cut complete tooth grooves, then the cutting insert structure remains simple, but production time increases and surface roughness remains high
Solution Approach 1:
The cutting insert combines multiple cutting edges at different depths to perform both roughing and finishing operations in a single pass, eliminating the need for multiple sequential passes and thereby increasing productivity while reducing total cutting time
Solution Approach 2:
The invention merges the roughing cut (first cutting edge) and finishing cut (second cutting edge) into a single integrated cutting operation. Both cutting edges operate simultaneously in one pass, combining multiple functions into one unified tool that reduces the number of passes required
3Loss of time
If a deeper cutting depth is achieved per pass, then fewer passes are required, but the surface roughness increases
Solution Approach 1:
The cutting insert divides the cutting depth into two distinct levels with two cutting edges. The first cutting edge operates at a deeper position to remove material efficiently, while the second cutting edge operates at a shallower position to provide a finishing cut that reduces surface roughness, thus achieving both deep cutting and smooth finish in one pass
Solution Approach 2:
The invention solves the contradiction by introducing a vertical dimension differentiation between cutting edges. Instead of increasing cutting depth uniformly, the second cutting edge is positioned higher (closer to the cutting direction) to provide a finishing pass that smooths the surface while the first cutting edge maintains the deeper material removal function
Data Source
Figure 1a~1c
Figure 1d~2
Figure 3~4
AI summary
Herein a cutting insert (2) for a power skiving tool is disclosed. The cutting insert (2) comprises an insert body (4) having a bottom surface (6) extending in a first plane (10), and a body axis (12) extending substantially in parallel with the first plane (10). The insert body (4) comprises a cutting end portion (14) and opposite thereto an abutment surface (18). The abutment surface (18) extends substantially perpendicularly to the body axis (12) and to the first plane (10). The cutting end portion (14) is provided with a first and a second cutting edge (20, 22), the first cutting edge (20) and the second cutting edge (22) being directed in a same cutting direction. Herein further a power skiving tool comprising such cutting inserts is disclosed.