Two-Corner Cutting Insert for Narrow-Gap Copy Machining
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Solution Overview
Problem
The machining of blisks made from difficult-to-cut materials like nickel-based alloys or titanium alloys in harsh environments poses challenges due to high cutting resistance, leading to potential machining defects and reduced accuracy, especially in narrow gaps of labyrinth seals.
Innovation Solution
A two-corner type cutting insert with a pair of lateral cutting edges forming an acute angle and a flat surface for increased contact area with the tool body, allowing for stable restraint and effective copy machining in narrow spaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a whole form bite or insert with a shape replicating the gap between protrusions is used, then it is possible to machine the narrow gap structure, but the cutting resistance is higher causing vibration and machining defects
Solution Approach 1:
The cutting insert is designed with a pair of lateral cutting edges that form an acute angle, segmenting the cutting action into two separate cutting points. This allows the tool to machine narrow gaps effectively while reducing overall cutting resistance and vibration compared to a single large cutting edge
Solution Approach 2:
The cutting insert uses a sharply pointed end portion with an acute angle between lateral cutting edges, changing the geometric parameters of the cutting edge. This sharp geometry reduces interference in narrow spaces and lowers cutting resistance while maintaining machining accuracy
2Manufacturing precision
If both end portions of the cutting insert are sharply pointed for narrow space machining, then copy machining in narrow spaces is enabled, but the contact area with tool body is small reducing restraint stability
Solution Approach 1:
The cutting insert has different geometries at different locations: the end portions are sharply pointed for effective narrow space machining, while the middle portion has a larger contact area with the tool body for stable restraint. This local differentiation of geometry resolves the contradiction between sharpness and stability
3Reliability
If a one-corner type cutting insert is used to stabilize restraint force, then the other end can be shaped specifically for restraint, but running cost increases compared to two-corner type
Solution Approach 1:
The cutting insert employs asymmetric geometry where one end portion is sharply pointed for cutting while the other end has a different geometry for restraint. This asymmetric design allows both cutting effectiveness and restraint stability in a single reusable insert, reducing running costs compared to disposable one-corner type inserts
Data Source
AI summary
Provided is a cutting insert or the like that is capable of copy machining in a narrow space and is also highly economical. A cutting insert (3) has a first end portion (4) and a second end portion (5) formed in substantially the same shape. A cutting edge (10) of the first end portion (4) includes a curved corner cutting edge (13) and a pair of lateral cutting edges (11 and 12) disposed such that both ends (13L and 13R) of the corner cutting edge (13) are sandwiched therebetween. The pair of lateral cutting edges (11 and 12) are formed linearly and form an acute angle (Y). A side surface (9) has a corner flank (94) continuous with the corner cutting edge (13) and a flat surface (95) disposed further toward a bottom surface (8) than the corner flank (94) at a portion (93) abutting on the corner cutting edge (13).