Effect of Insert Angles on Cutting Tool Geometry

An analysis of publications has shown that mechanically clamped indexable inserts are predominantly used in modern tool manufacturing. Each insert has its shape and geometry in the tool coordinate system. The static system’s required geometry is achieved by the tilting of the insert pocket in the radial and axial directions. Therefore, it is of great importance in the tool design to know the relationships between the insert’s geometry parameters in the tool coordinate system where the geometry paraments of the insert are defined and working geometry parameters of the tool defined in the static coordinate system. The paper presents the developed methodology for determining the insert pocket base surface position to ensure the required values of the tool geometry parameters of the selected indexable insert in the static coordinate system. The graphs of the dependence of each of the angles of the insert geometry on the angles of rotation of this insert in the front and profile planes are presented as the level lines for practical use. Using these graphs, one can optimize all geometric insertion parameters in the static coordinate system. The model of the calculations of the mechanism of the insert clamping by a screw is developed. The basic size and tolerance of the output link determine the distance from the intersection line of the base surfaces to the thread axis on the pocket and the minimum amount of the screw stroke on the insert clamping in the pocket. Keywords: indexable insert, cutting tool, coordinate system, base surfaces, geometric parameters.

Measurement of the Temperature Distribution at the Tool-Chip Interface by Using a Cutting Tool with Seven Pairs of Built-In Micro Cu/Ni Thermocouples

Knowing temperatures at the tool-chip interface is extremely important to optimize the machining condition and to improve the machining performance, furthermore to design high performance materials. In order to grasp the temperature distribution at the tool-chip interface, this study has devised an indexable insert with seven pairs of built-in micro Cu/Ni thermocouples on the rake face near the cutting edge. This paper shows the performance of the indexable insert with built-in micro thermocouples developed. The thickness of each element of the micro thermocouple is approximately 15 μm. The result of unsteady heat conduction analysis employing FEM shows that the temperature difference by installing the micro thermocouples is less than 10 K or 1.2 %. The temperature measurement experiments by cutting of aluminum alloy were carried out by changing the cutting speed. The results provided the evidence that the temperature distribution at the tool-chip interface can be grasped with the indexable insert with built-in micro thermocouples developed.