Sinusoidal Helical Cutting Inserts for Precision Machining

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Solution Overview

Problem

Modular rotary cutting tools with indexable inserts face challenges in forming a true helical cutting edge, leading to rough surface finishes and uneven machining due to alignment issues and non-linear cutting edge patterns, which are exacerbated by the use of sinusoidal or wavelike cutting edges.

Innovation Solution

The development of cutting inserts with a combined sinusoidal and helical cutting edge geometry, where each point on the cutting edge is located at a constant distance from the tool's central axis, forming a true helical shape that maintains a smooth and accurate cutting path, and a design method to align multiple inserts on a tool holder to create a cutting flute with a sinusoidal and helical edge.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If indexable cutting inserts are used to form helical cutting edges, then the cutting tool is more economical and allows replacement of worn inserts, but the alignment of multiple inserts creates non-linear cutting edge patterns that result in rough surface finishes and uneven machining

Engineering Contradiction:

Improvetool life and cost-effectivenessVSAvoidsurface finish quality

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The cutting tool is divided into modular indexable inserts that can be independently replaced. Each insert contains a portion of the helical cutting edge geometry, and when properly aligned, these segmented inserts collectively form a continuous helical cutting edge pattern that maintains surface finish quality while enabling insert replacement.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The insert pockets are pre-configured with specific angular positions and orientations that correspond to the helical cutting edge geometry. This preliminary positioning ensures that when inserts are installed, they automatically align to form the correct helical pattern, eliminating the need for post-installation alignment adjustments and ensuring consistent surface finish.

Inventive Principle:

Principle #10Preliminary action

2Productivity

If sinusoidal or wavelike cutting edges are used on indexable inserts, then the cutting action may be improved, but the alignment issues are exacerbated and the helical shape is compromised

Engineering Contradiction:

Improvecutting actionVSAvoidhelical shape accuracy

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

Each cutting insert is designed with specific local geometry features including sinusoidal or wavelike cutting edge profiles that are optimized for the local cutting conditions. The inserts are positioned at specific locations around the tool holder where their local geometry contributes to the overall helical cutting action, with each insert's geometry tailored to its specific position and function.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The cutting edges incorporate sinusoidal and wavelike curved geometries that improve cutting action by creating a more gradual engagement with the workpiece. These curved profiles are integrated into the helical arrangement, where the curvature of individual inserts combines to form the continuous helical surface, maintaining both cutting performance and geometric accuracy.

Inventive Principle:

Principle #14Spheroidality (Curvature)

3Adaptability or versatility

If multiple cutting inserts are assembled on a tool holder to form a helical cutting edge, then the cutting tool can be modular and replaceable, but alignment difficulties prevent formation of a true helical shape

Engineering Contradiction:

Improvemodular replaceabilityVSAvoidhelical geometry accuracy

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The modular insert system is designed to be self-aligning through precision-machined pocket geometries and insert features. The inserts automatically assume their correct positions and orientations when installed in the pockets, with the pocket geometry itself providing the alignment reference, thereby eliminating the need for external alignment tools or procedures and ensuring consistent helical geometry.

Inventive Principle:

Principle #25Self-service

Data Source

PatentEP2741883B1Cutting insert and cutting tool having sinusoidal and helical cutting edges

Publication Date: 2020.10.07 KENNAMETAL INC

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AI summary

A cutting tool system (140) is designed to have a combined sinusoidal-shaped and helical- shaped cutting edge formed by an assembly of aligned common cutting inserts (147c, 147b, 147d) each having a sinusoidal and helical cutting edge.