Threading Insert Edge Roundness for Wear and Surface Finish

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Solution Overview

Problem

Existing threading inserts face challenges with wear and surface quality in metal cutting operations, particularly in threading processes, where vibrations and cutting forces can lead to reduced tool life and inferior thread profiles.

Innovation Solution

The threading insert features a cutting edge with varying edge roundness along its length, which optimizes edge strength and cutting forces, reducing wear and improving surface finish by employing a rounded edge design that can be achieved through abrasive processes or EDM, allowing for enhanced chip breaking and tool longevity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Force

If a sharp cutting edge is used, then cutting forces are reduced, but edge strength decreases and wear increases

Engineering Contradiction:

Improvecutting forcesVSAvoidedge strength

Core Design Contradiction:

ForceVSStrength

Solution Approach 1:

The cutting edge is designed with non-uniform roundness distribution along its length, creating different local geometries: the first portion has greater roundness for enhanced edge strength and wear resistance, while the second portion has lesser roundness for reduced cutting forces and better surface finish. This local differentiation resolves the contradiction between edge strength and cutting forces.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The edge roundness parameter is varied along the cutting edge length, transitioning from a uniform value to a non-uniform distribution. Specifically, the roundness radius changes from a first value at the first portion to a second value at the second portion, allowing optimization of both edge strength and cutting performance simultaneously.

Inventive Principle:

Principle #35Parameter changes

2Strength

If a rounded cutting edge is used, then edge strength and wear resistance are improved, but surface quality of the machined thread deteriorates

Engineering Contradiction:

Improveedge strengthVSAvoidsurface quality

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

Different portions of the cutting edge are assigned different roundness characteristics: the first portion with greater roundness provides edge strength and wear resistance, while the second portion with lesser roundness maintains surface quality. This local differentiation allows both requirements to be satisfied simultaneously.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The cutting edge is divided into two distinct portions along its length, each with different roundness values. The first portion (with greater roundness) handles the demanding cutting action, while the second portion (with lesser roundness) ensures smooth surface finish, effectively segmenting the functions to resolve the contradiction.

Inventive Principle:

Principle #1Segmentation

3Ease of manufacture

If uniform edge roundness is applied along the cutting edge, then manufacturing is simplified, but optimal performance in terms of wear and surface finish cannot be achieved

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidinsert wear resistance

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The cutting edge is designed with non-uniform roundness distribution, where the first portion has greater roundness for enhanced wear resistance and the second portion has lesser roundness for optimal surface finish. This local differentiation improves reliability while the overall rounded design maintains reasonable manufacturability through processes like selective grinding or EDM.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The edge roundness is made variable along the length of the cutting edge rather than uniform, creating a dynamic geometric profile that adapts to different functional requirements at different locations. This allows optimization of wear resistance and surface finish simultaneously while maintaining manufacturability through controlled variation.

Inventive Principle:

Principle #15Dynamics

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This design enhances the efficiency of threading operations by reducing insert wear, improving surface quality, and minimizing vibrations, resulting in longer tool life and higher quality thread profiles, especially in modified flank infeed operations and when used with cemented carbide materials.

Implementation Method 1

a beam comprising an abrasive medium is directed towards the first cutting edge

Methodology Applied

Scientific EffectAbrasion: Abrasion

Implementation Method 2

employing a rounded edge design that can be achieved through abrasive processes or EDM

Methodology Applied

Scientific EffectElectrical discharge machining: Electrical Discharge Machining

Data Source

PatentUS11772165B2Threading insert having variable edge roundness

Publication Date: 2023.10.03 SANDVIK INTELLECTUAL PROPERTY AB

AI summary

A threading insert includes a top surface, an opposite bottom surface, a side surface connecting the top surface and the bottom surface, and a first tooth. The first tooth has a first cutting edge, the first cutting edge including a first top cutting edge connecting a first leading cutting edge and a first trailing cutting edge. The first cutting edge has an edge roundness and the size of the edge roundness varies along the first cutting edge.