Prismatic Cutting Insert Combining Roughing and Finishing Edges
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Solution Overview
Problem
Existing methods for machining rotating workpieces like crankshafts require multiple cutting inserts with different geometries for rough and fine machining, leading to increased tool costs, storage complexity, and long setup times due to the need for various indexable inserts and multiple tools.
Innovation Solution
A cutting insert with parallel upper and lower surfaces and perpendicular side surfaces, featuring round cutting corners and comb-like cutting edges, which allows for combined radial and axial machining, reducing the number of required indexable inserts and simplifying tool assembly, while incorporating a central plateau for secure clamping and chip management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple cutting inserts with different geometries are used for rough and fine machining, then machining precision is improved, but device complexity increases
Solution Approach 1:
The patent combines roughing and finishing cutting edges on a single cutting insert. The insert features both roughing cutting edges with larger rake angles and finishing cutting edges with smaller rake angles, eliminating the need for multiple specialized inserts and reducing tool complexity while maintaining machining precision
Solution Approach 2:
The cutting insert is designed with multi-functionality to perform both roughing and finishing operations. By incorporating different types of cutting edges (roughing and finishing) on the same insert, the tool can adapt to different machining stages without requiring tool changes or multiple specialized inserts
2Manufacturing precision
If multiple cutting inserts are used for different machining operations, then machining precision is improved, but loss of time increases
Solution Approach 1:
The patent merges roughing and finishing capabilities into a single cutting insert, eliminating the need to change between different inserts for different machining operations. This reduces setup time and tool change overhead while maintaining the precision benefits of specialized cutting edges
3Manufacturing precision
If multiple cutting inserts are used for rough and fine machining, then machining precision is improved, but quantity of substance increases
Solution Approach 1:
The patent combines multiple cutting edge types on a single insert, reducing the total number of inserts and associated tooling inventory required. This decreases the quantity of tooling material and storage space needed while maintaining machining precision through the integrated roughing and finishing edges
Data Source
Figure 1
Figure 2~3
AI summary
The invention relates to a cutting insert with a prismatic base form, with an upper and a lower surface (11), arranged parallel to each other and connected by four lateral surfaces perpendicular thereto, of which two opposing lateral surfaces (14) have projecting and recessed sections, which, together with the upper and lower surfaces form corrugated cutting edges and of which the two remaining opposing lateral surfaces (13) are arranged planar and parallel to each other. According to the invention, at least one cutting corner (18) formed by two adjacent lateral surfaces (13, 14) has an embodiment as a cutting edge. The invention further relates to a method with application of the disclosed cutting insert which firstly, for facing a central bearing, is radially displaced on a rotated workpiece and then, for finishing a bearing surface, is axially displaced.