Three-Nose Turning Insert for External 90° Corner Machining
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Solution Overview
Problem
Existing turning inserts face challenges in machining external 90° corners, particularly in out-facing operations, where chip control and insert wear are poor, leading to reduced tool life and surface quality.
Innovation Solution
A turning insert with three nose portions, featuring a nose angle of 25-50° and a unique geometry that allows the same active nose portion to be used for both axial and radial feeds without reorientation, improving chip breaking and tool life by optimizing cutting edge angles and chip flow direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If common turning inserts (TNMG or TCMT) with 60° nose angle are used for out-facing operations, then the insert can be used for a wide range of feed directions, but chip control is poor and insert wear increases
Solution Approach 1:
The patent applies local quality by providing different nose angles for different nose portions of the turning insert. Specifically, at least one nose portion has a nose angle of 25°-50° optimized for out-facing operations to improve chip control, while other nose portions may have different angles (such as 60°) suitable for other feed directions. This allows each nose portion to have locally optimized geometry for its specific function, resolving the contradiction between versatility and chip control.
2Ease of manufacture
If common turning inserts with 60° nose angle are used for out-facing, then the insert structure is simple and easy to manufacture, but insert wear is poor and tool life is reduced
Solution Approach 1:
The patent implements local quality by assigning different nose angles to different nose portions. At least one nose portion features a nose angle of 25°-50° specifically optimized for out-facing operations to reduce insert wear and extend tool life, while maintaining the overall simple insert structure that is easy to manufacture. This localized optimization allows the insert to achieve better wear resistance without significantly complicating the manufacturing process.
3Device complexity
If the same active nose portion is used for both axial and radial feeds, then the device complexity is reduced and operation is simplified, but the cutting edge angles must be optimized for multiple feed directions simultaneously
Solution Approach 1:
The patent applies universality by designing the turning insert so that the same active nose portion can be used for both axial and radial feed directions without requiring reorientation of the insert. The nose portion is engineered with a nose angle of 25°-50° and specifically optimized cutting edge angles that perform effectively in multiple feed directions, eliminating the need for reorientation and reducing device complexity while maintaining manufacturing feasibility.
4Productivity
If conventional turning inserts are used for machining external 90° corners, then the machining process is simple, but surface quality is poor and chip breaking is inadequate
Solution Approach 1:
The patent applies local quality by providing at least one nose portion with a nose angle of 25°-50° specifically optimized for machining external 90° corners. This localized geometric optimization improves chip breaking and surface quality in corner machining operations while maintaining the overall simplicity of the machining process. The specific nose angle configuration enables better chip control and surface finish without complicating the machining procedure.
Data Source
AI summary
A turning insert includes a top surface, an opposite bottom surface, a reference plane located parallel to and between the top surface and the bottom surface, and a center axis extending perpendicular to the reference plane and intersecting the reference plane (RP), the top surface and the bottom surface. Side surfaces connect the top surface and the bottom surface. Three nose portions are formed symmetrically relative to the center axis. Each nose portion includes a first cutting edge, a second cutting edge and a convex nose cutting edge connecting the first) and second cutting edges. In a top view the first and second cutting edges on the same nose portion form a nose angle of 25-50° relative to each other. The distance from the first cutting edge to the reference plane varies in such a way that that this distance is decreasing at increasing distance from the nose cutting edge.