Turning Tool Inserts With Dual Edge Angles for Fewer Tool Changes
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Solution Overview
Problem
Current turning tools lack versatility in performing a variety of turning operations, requiring frequent tool changes during manufacturing processes.
Innovation Solution
A turning tool kit with multiple cutting inserts, each with unique cutting edge geometries and angles, allowing for selective use in the same tool body to accommodate different machining operations, reducing the need for tool changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single cutting insert geometry is used in the turning tool, then the tool design is simple, but the versatility for different machining operations is limited
Solution Approach 1:
The cutting insert is designed with multiple cutting edges (at least two) with different geometries on the same insert body, allowing a single insert to perform multiple turning operations such as roughing and finishing. This multi-functionality approach enables one insert to replace what would traditionally require multiple specialized inserts, thereby improving versatility without proportionally increasing complexity.
Solution Approach 2:
The cutting insert is divided into distinct functional zones with different cutting edges, where each cutting edge has optimized geometry for specific machining tasks. The insert body is segmented to accommodate multiple cutting edges with varying angles and profiles, allowing selective use of appropriate cutting edges based on the required operation.
2Reliability
If multiple specialized turning tools are used for different operations, then each operation can be performed optimally, but the number of tool changes increases
Solution Approach 1:
By integrating multiple cutting edges with different geometries on a single cutting insert, the tool can perform various turning operations (roughing, finishing, different feed directions) without requiring tool changes. This maintains machining quality through optimized geometries while improving productivity by eliminating tool change interruptions.
Solution Approach 2:
The multiple cutting edges are arranged to allow continuous machining operations without tool changes. After one cutting edge becomes dull, the tool can be repositioned to use another cutting edge on the same insert, maintaining continuous productive action and eliminating downtime associated with tool changes.
3Adaptability or versatility
If cutting edges with different geometries are integrated on the same insert, then versatility is improved, but the insert design becomes more complex
Solution Approach 1:
Different regions of the cutting insert are designed with locally optimized cutting edge geometries tailored to specific machining requirements. Each cutting edge has its own unique profile, angle, and shape optimized for particular operations, while the overall insert structure remains standardized for easy mounting and replacement.
Data Source
Figure 1~2c
Figure 3a~5b
Figure 6~7
AI summary
The invention relates to a turning tool kit (100) for turning operations, comprising a tool body (1) and at least a first cutting insert (6) and a second cutting insert (6'), each cutting insert being selectively arrangeable in a seat (5) in the tool body. Each of the first and the second cutting inserts (6, 6') includes at least two cutting edges (10, 10'), each cutting edge including a nose cutting edge (101, 101') separating and connecting a forward cutting edge (102, 102') and a rearward cutting edge (103, 103'). The forward cutting edge (102) of each of the at least two cutting edges (10) on the first cutting insert (6) forms a first acute angle (A) to the respective rearward cutting edge (103), whereas the forward cutting edge (102') of each of the at least two cutting edges (10') on the second cutting insert (6') forms a second acute angle (B) to the respective rearward cutting edge (103'), wherein the second acute angle (B) is greater than the first acute angle (A). The forward cutting edge (102') of each of the at least two cutting edges (10') on the second cutting insert (6') transitions into an auxiliary non-cutting edge (104') that forms an angle to the respective rearward cutting edge (103') that is the same, or substantially the same, as the first acute angle (A). The invention also relates to a cutting insert (6', 6") for use in such a turning tool kit.