Rotary Cutting Insert Geometry for Stable Deep Profiling
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Solution Overview
Problem
Conventional indexable rotary cutting tools experience chattering vibration and bending when performing deep engraving or profiling processes on high-toughness and high-hardness materials, particularly with long tool protrusion lengths, leading to chipping and reduced accuracy.
Innovation Solution
The indexable rotary cutting tool features a specific geometry with a twist angle and rake angles for the outer peripheral and corner cutting edges, including a chamfered surface, which enhances chip discharge and prevents excessive biting, thereby stabilizing the cutting process even with long tool protrusion lengths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a long tool protrusion length is used for deep engraving or profiling processes, then the tool can reach deep recesses and perform complex machining operations, but the tool is easily bent due to reaction forces and experiences chattering vibration
Solution Approach 1:
The patent changes the geometric parameters of the cutting edge, specifically setting the radial rake angle to a negative value in the region from the boundary point to the reference point on the cutting edge of the corner. This parameter modification increases cutting edge strength and prevents excessive biting, allowing the tool to maintain stability even with long protrusion lengths required for deep engraving and profiling operations
2Productivity
If the cutting edge geometry has a positive radial rake angle, then chip flow is improved, but the cutting edge becomes weaker and more prone to chipping and excessive biting
Solution Approach 1:
The patent applies local quality by creating different rake angle conditions at different locations on the cutting edge. The radial rake angle is negative in the region from the boundary point to the reference point on the cutting edge of the corner to strengthen that specific area, while other regions may have different angle characteristics to maintain overall cutting performance and chip flow
3Adaptability or versatility
If the tool performs face milling on high-toughness and high-hardness materials, then valuable workpieces can be processed, but the cutting edge experiences excessive biting leading to chipping and chattering vibration
Solution Approach 1:
The patent modifies the radial rake angle parameter to a negative value in the critical region of the cutting edge of the corner, which increases the cutting edge strength and prevents excessive biting when machining high-toughness and high-hardness materials, thereby improving reliability
Data Source
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AI summary
Provided is an indexable rotary cutting tool comprising wherein, a twist angle of the outer peripheral cutting edge (9) has a positive value, an axial rake angle (Ar1) of the cutting edge (13) of the corner R at a boundary point (Q) between the cutting edge (13) of the corner R and the outer peripheral cutting edge (9) has a positive value, the axial rake angle (Ar2) of the cutting edge (13) of the corner R at the reference point (RP) has a negative value, at least the radial rake angle (δ) in a region between the boundary point (Q) and the reference point (RP) in an entire edge length region of the cutting edge (13) of the corner R has a negative value, and the radial rake angle (Ar2) of the cutting edge (13) of the corner R at the reference point (RP) is smaller than the radial rake angle (Ar1) of the cutting edge (13) of the corner R at the boundary point (Q).