Polygonal Cutting Inserts for High-Feed Milling on Curved Surfaces
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Solution Overview
Problem
High feed cutting methods are not effectively applicable to machining curved surfaces due to limitations in cutting depth and feed rates when using traditional round cutting inserts with tilted spindle axes, which are necessary for complex shapes like turbine blades.
Innovation Solution
The method involves using substantially polygonal cutting inserts with a tool-inherent lead angle between 20° and 40°, allowing the spindle axis to tilt, thereby adjusting the effective lead angle between 5° and 20° to enable high feed cutting on complex surfaces by compensating for the slanted position, allowing for increased cutting depths and feed rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a spindle axis is tilted to machine curved surfaces, then the ability to follow complex surface contours is improved, but the lead angle becomes too large which reduces the maximum achievable axial cutting depth
Solution Approach 1:
The invention changes the geometric parameters of the cutting insert by using a polygonal base shape with specifically designed lead angles (20°-40°) instead of traditional round inserts. This parameter change allows the insert to maintain suitable effective lead angles (5°-20°) even when the spindle axis is tilted, thereby resolving the contradiction between adaptability to curved surfaces and achievable axial cutting depth.
2Ease of operation
If a spindle axis is tilted for complex shaped workpieces, then the ability to free up straight cutting inserts is improved, but the cutting depth is limited by the reduced lead angle
Solution Approach 1:
The polygonal cutting insert design with predetermined lead angles (20°-40°) fundamentally changes the geometric parameters to accommodate spindle tilting. This allows the cutting insert to be freely positioned and indexed while maintaining optimal effective lead angles during tilted spindle operations, thus resolving the contradiction between ease of operation and cutting depth limitations.
3Ease of manufacture
If traditional round cutting inserts are used with tilted spindle axis, then the setup is simple, but the feed rates and cutting depths must be reduced which lowers productivity
Solution Approach 1:
The invention employs polygonal cutting inserts with specifically engineered lead angles (20°-40°) that are optimized for tilted spindle operations. This parameter change enables maintenance of high feed rates (0.7-3 mm/tooth) and adequate cutting depths even when the spindle axis is tilted, thereby resolving the contradiction between manufacturing simplicity and productivity.
Data Source
AI summary
A method for milling a workpiece by way of at least one substantially polygonal cutting insert, which is arranged in a tool holder. A spindle axis of the tool holder encloses an angle of more than 0° with a plane normal to a machined workpiece surface. An effective lead angle between a main cutting edge of the cutting insert and the machined workpiece surface lies between 0° and 20°.