Multi-Insert Turning Tool for Deep Cuts and Chip Control
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Solution Overview
Problem
Existing turning tools are not versatile, cost-effective, and generate undesirable broad chips during machining of hard metals, particularly when large volumes need to be removed.
Innovation Solution
A turning tool with multiple insert seats and cutting inserts, each with distinct cutting edges, allowing simultaneous cutting in multiple directions and depths, optimizing chip control and reducing tool material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a larger cutting insert is used to remove large volumes of workpiece, then the material removal rate is improved, but the chip width becomes broader and more difficult to manage, and the cost increases
Solution Approach 1:
The cutting insert is divided into multiple separate cutting edges (first axial cutting edge, first radial cutting edge, second axial cutting edge, second radial cutting edge) that can cut simultaneously or sequentially. This segmentation allows the total cutting depth to be distributed across multiple narrower cutting edges, achieving high material removal rate while maintaining manageable chip widths.
2Productivity
If a larger cutting insert is used to remove large volumes of workpiece, then the material removal rate is improved, but the cost increases
Solution Approach 1:
Instead of using one large expensive cutting insert, the solution uses multiple smaller cutting edges on a single insert. This segmented approach reduces the cost per cutting edge while maintaining high productivity through simultaneous or sequential cutting actions.
Solution Approach 2:
The cutting insert is designed with multiple cutting edges that can be dynamically activated based on the machining requirements. The insert can be indexed to bring different cutting edges into position, providing flexibility and extending the tool life, which reduces overall machining cost.
3Adaptability or versatility
If multiple cutting inserts are used to perform longitudinal external turning, then the versatility is improved, but the device complexity increases
Solution Approach 1:
Multiple cutting edges that would traditionally require separate cutting inserts are merged into a single cutting insert. The insert contains first and second axial cutting edges and first and second radial cutting edges, all integrated into one component that can be mounted on the tool holder.
Solution Approach 2:
The cutting insert is designed with multi-functionality, containing cutting edges that can perform both axial and radial cutting operations. This universal design allows a single insert to handle various turning operations (longitudinal and crosswise) without requiring multiple specialized inserts, thus improving versatility while reducing complexity.
Data Source
Figure 1a~1b
Figure 2a
Figure 2b
AI summary
The invention relates to a turning tool (1) comprising a tool body (10) having a plurality of insert seats (94, 95, 95') at a front end (FE) thereof. A mounted first cutting insert (41) has a front point located axially most forward of all points on all cutting edges of the tool. The first cutting edge has a radial point located radially most outward of all points on all cutting edges of the tool. The first cutting insert has a side cutting edge for machining a workpiece (20) in an axial direction thereof and a side cutting edge for machining the workpiece in a radial direction thereof. A second cutting insert (95; 95') is arranged so that a side surface thereof forms a continuation of one of the side cutting edges of the first insert. The first and second insert is in cut simultaneously, in the axial or radial direction. More cutting inserts may be provided in a similar way to achieve a large cutting depth during a pass in the axial or radial direction. The total cutting depth during a pass is the sum of a number of cutting depths (Ap1, Ap2).