Turning Tool Orientation for Fine Surface Finish at High Feed Rates
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Solution Overview
Problem
Existing turning apparatuses face challenges in achieving desired cutting force and surface roughness for machining rotationally symmetric surfaces, particularly in balancing high surface quality for minimal wear and effective lubrication, while also improving cutting efficiency.
Innovation Solution
The method involves rotating the workpiece around a rotational axis and positioning the cutting tool with a cutting edge at an angle relative to the feed direction, where the rake face's normal is tilted between 35° to 60° and the cutting edge is oriented to maintain effective contact, ensuring good surface roughness and toughness, with a feed rate between 0.2 mm to 1.2 mm per revolution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional turning operations are used with standard cutting tool orientation, then machining can be performed, but surface roughness quality deteriorates at high feed rates
Solution Approach 1:
The cutting tool is oriented asymmetrically relative to the workpiece, with the rake face normal tilted at an angle α between 35° and 60° from the radial direction. This asymmetric orientation optimizes the cutting action to produce superior surface roughness quality even at elevated feed rates, resolving the contradiction between surface quality and productivity.
Solution Approach 2:
The invention changes the geometric parameters of the cutting tool orientation, specifically tilting the rake face normal by angle α (35°-60°) and angle δ (0°-15°) relative to standard positions. These parameter changes enable the cutting edge to interact with the workpiece in a manner that maintains fine surface finish at higher feed rates than conventional turning.
2Productivity
If higher feed rates are used to improve productivity, then cutting efficiency increases, but surface roughness quality deteriorates
Solution Approach 1:
By orienting the cutting tool asymmetrically with rake face normal tilted at angle α (35°-60°) from the radial direction, the cutting action is optimized to maintain surface roughness quality even when operating at higher feed rates for improved productivity.
Solution Approach 2:
The cutting tool orientation is dynamically optimized for different machining conditions, allowing the system to achieve both high feed rates and good surface finish by adapting the rake face angles to the specific cutting requirements.
3Productivity
If cutting force is increased to improve material removal rate, then productivity increases, but surface quality and toughness deteriorate
Solution Approach 1:
The invention optimizes the cutting parameters by setting specific ranges for rake face tilt angles (α: 35°-60°, δ: 0°-15°), which balance the cutting force components to achieve both high material removal rate and superior surface quality with appropriate toughness.
Data Source
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AI summary
In accordance with various illustrative embodiments of the present disclosure, a rotationally symmetric surface of a workpiece is machined by a turning apparatus, wherein the workpiece is rotationally driven around a rotational axis, a cutting tool with a cutting edge positioned at the edge of a rake face is arranged relative to the workpiece, the cutting tool is brought into contact with the workpiece, and the cutting tool is advanced relative to the workpiece along a feed direction parallel to the rotational axis, the normal to the rake face being tilted relative to the feed direction, a first axis and a second axis, the first axis and the second axis are perpendicular to the feed direction and perpendicular to each other.