Rotating Turning Insert for Large Workpiece Machining
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Solution Overview
Problem
Conventional turning inserts in metal machining experience high wear and reduced service life due to heat buildup when stationary, and existing rotating tools are cumbersome for large workpieces, making it difficult to face turn end surfaces effectively.
Innovation Solution
A turning insert that rotates around its own axis, with a chip surface design featuring a circumferential first portion and a second portion with chip breaking means, allowing continuous feeding of a new cutting edge and efficient chip breaking, enabling machining of large workpieces with reduced tool length and vibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the turning insert is made stationary, then the structure is simple, but the service life becomes short due to heat buildup and wear
Solution Approach 1:
The turning insert is designed to rotate around its own axis during machining operations. This dynamic element allows different portions of the cutting edge to sequentially engage with the workpiece, distributing heat and wear across the entire circumference rather than concentrating them at a single stationary point, thereby extending service life while maintaining operational simplicity
2Duration of action of moving object
If the turning insert rotates around its own axis, then the service life increases, but the tool becomes longer and more slender
Solution Approach 1:
The rotation of the turning insert around its own axis enables a longer cutting edge to be effectively utilized without requiring a proportionally longer tool body. As the insert rotates, different angular positions of the cutting edge engage the workpiece, allowing the active cutting portion to extend further while the tool support structure remains compact
3Duration of action of moving object
If the tool is made longer to accommodate rotating insert, then the service life increases, but the risk of tool contact with workpiece increases
Solution Approach 1:
The rotating turning insert is positioned and oriented such that its rotation plane is substantially perpendicular to the workpiece axis. This dynamic configuration, combined with controlled rotation, ensures that only the intended cutting edge portions contact the workpiece during machining, preventing unintended tool-body contact even when the tool spans a larger distance
4Temperature
If the turning insert rotates at high speed, then the cutting edge temperature decreases, but the device complexity increases
Solution Approach 1:
The turning insert is designed with a rotation mechanism that spins the insert around its own axis during machining. This dynamic rotation creates a cooling effect by continuously bringing fresh portions of the cutting edge into contact with the workpiece and exposing heated areas to cooler regions, effectively reducing cutting edge temperature without requiring complex external cooling systems
Solution Approach 2:
The rotating turning insert system is designed to be self-cooling through its own rotation motion. The rotational movement itself generates the thermal management effect by cycling different portions of the cutting edge through heated and cooled states, eliminating the need for separate cooling mechanisms and maintaining device simplicity
Data Source
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AI summary
The invention relates to a turning insert, a tool part, a method and a machine tool for chip-cutting metal machining of a workpiece (3). The workpiece rotates in a first direction of rotation (R) at a first speed of rotation around a workpiece axis (C1). The turning insert (9) comprises a front surface, an envelope surface and a circular cutting edge located where the front surface meets the envelope surface. The cutting edge extends around the front surface and is lying in a plane that forms an angle α with the envelope surface. A tool axis (C2) extends through the turning insert in a normal direction in respect of said plane. The turning insert is, during the chip-cutting metal machining, formed to rotate around the tool axis (C2) at a second speed of rotation. The envelope surface forms a chip surface and is arranged to meet chips formed in the chip-cutting metal machining. The chip surface comprises chip breaking means.