Turning Insert with Dual Nose Angles for Out-Facing
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Solution Overview
Problem
Conventional turning inserts experience poor chip control and rapid insert wear when used for out-facing operations in metal cutting, particularly when machining 90° corners, leading to suboptimal surface finish and increased tool wear.
Innovation Solution
A new turning insert design featuring two nose portions with specific cutting edge geometries, including a convex nose cutting edge and adjacent cutting edges forming angles of 70-85° and 0-34° relative to the bisector, allows for improved chip breaking and control during axial and radial feeds, reducing insert wear and preventing chip jamming.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional turning inserts (DNMG or DCMT) are used for out-facing operations, then radial feed away from the rotational axis is possible, but poor chip control and fast insert wear occur
Solution Approach 1:
The turning insert features different cutting edge geometries at different locations: the first and second cutting edges have specific angle ranges (30-45° and 15-30° respectively) optimized for out-facing operations, while the third and fourth cutting edges have different angle ranges (10-25° and 5-15° respectively) for axial turning. This localized optimization of cutting edge geometry at each position resolves the contradiction by providing location-specific quality tailored to the operational requirements of each cutting edge.
2Productivity
If conventional turning inserts are used for out-facing, then radial feed is achievable, but chip jamming and poor surface finish result
Solution Approach 1:
The patent applies parameter changes by specifying precise angle ranges for different cutting edges: the first cutting edge angle (30-45°) and second cutting edge angle (15-30°) are optimized for out-facing operations to achieve proper chip control and surface finish. This systematic variation of geometric parameters resolves the contradiction between productivity and manufacturing precision by tuning the cutting edge angles to optimal values for the specific operation.
3Ease of operation
If axial turning towards the clamping end is performed with conventional inserts, then the surface generating nose cutting edge is ahead of the active main cutting edge, but this causes suboptimal chip control and increased insert wear
Solution Approach 1:
The patent inverts the conventional configuration by positioning the surface generating nose cutting edge behind the active main cutting edge (first or second cutting edge) during axial turning away from the clamping end. This inversion of the traditional geometry arrangement resolves the contradiction by reversing the relative positions of cutting edges to achieve superior chip control and reduced insert wear, directly applying the 'other way round' principle.
4Reliability
If a larger nose angle is used to reduce insert wear, then insert durability improves, but the ability to machine 90° corners is compromised
Solution Approach 1:
The patent segments the cutting insert into multiple distinct cutting edges (first, second, third, and fourth cutting edges) with different angle optimizations. The first and second cutting edges have larger angles (30-45° and 15-30°) for wear resistance, while the third and fourth cutting edges have smaller angles (10-25° and 5-15°) for machining 90° corners. This segmentation resolves the contradiction by distributing different functional requirements to different segments of the insert.
Solution Approach 2:
The turning insert achieves multi-functionality by incorporating cutting edges with different angle ranges that can handle various operations: out-facing, axial turning, and 90° corner machining. The first cutting edge (30-45°) and second cutting edge (15-30°) serve out-facing and axial turning, while the third cutting edge (10-25°) and fourth cutting edge (5-15°) are optimized for 90° corner work. This universality allows a single insert to perform multiple functions with optimized performance for each.
Data Source
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AI summary
The invention relates to a turning insert (1) comprising a top surface (8), an opposite bottom surface (9), side surfaces (13, 13') connecting the top surface (8) and the bottom surface (9), and two opposite nose portions (15, 15'). Each nose portion (15, 15') comprising a convex nose cutting edge (10, 10'), a first cutting edge (11, 11') and a second cutting edge (12, 12'). The convex nose cutting edge (10, 10') connects the first (11, 11') and second (12, 12') cutting edges. A reference plane (RP) is located parallel to and between the top surface (8) and the bottom surface (9). A center axis (A1) extends perpendicular to the reference plane (RP). A bisector (7) extends equidistantly from the first (11) and second (12) cutting edges. In a top view the first (11) and second (12) cutting edges on the same nose portion (15) form a nose angle (α) of 70-85° relative to each other. Each nose portion (15, 15') comprises a third convex cutting edge (60) adjacent to the first cutting edge (11) and a fourth cutting edge (61) adjacent to the third cutting edge (60). In a top view the fourth cutting edge (61) forms an angle (β) of 0-34° relative to the bisector (7). The distance from the forth cutting edge (61) to the reference plane (RP) is decreasing away from the nose cutting edge (10).