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Talking about the evolution of cutting inserts
Background: As the times have changed, the shape of the cutting tool and the geometry of the cutting edge have undergone a series of interesting evolutions. With the unremitting pursuit of higher production efficiency and processing efficiency, the development of new alloy grades and introduction to the production workshop has prompted the accelerated evolution of smart precision tools. Objectively speaking, the metal cutting indexable inserts have evolved, their geometric parameters have been continually corrected, and the shape has undergone several redesigns. In the mid-20th century, the International Organization for Standardization (ISO) promulgated the ISO standard, which specifies the specific dimensions and characteristics that should be followed for the manufacture of indexable inserts, with the aim of ensuring the compatibility of indexable inserts and sipe from different manufacturers. ISO standards are the norms that machine operators, installation coordinators, and production team leaders have consistently implemented, but the new technological revolution has spawned a series of very differently designed tools that not only have impressive geometries, but also meet various industries. The demanding requirements for high speed tools also maintain a long life per blade. Origin: In order to improve production efficiency and achieve rapid metal cutting (FMR), people continue to set aside the ISO standard and pursue precise and unique cutting edge geometry design. One way to achieve these goals is to find a way to increase cutting speed and feed rate, cutting off large amounts of material in the shortest possible time. However, attempts to improve the geometry of the blade to improve machining efficiency have met the constraints of low power, low torque, and insufficient clamping force of the low-power CNC machining center. With these limitations in mind, tool manufacturers have focused their efforts on blade cutting edges that offer lower cutting forces. When the cutting force is reduced, even if the tool feed amount and cutting speed are increased, the machining operation of the tool can be made relatively stable; and, because the cutting force is reduced, the vibration can be reduced to some extent. The development of ultra-fine grained carbide substrates, combined with a series of excellent heat and wear resistant coatings, as well as advanced powder metal pressing technology, have jointly promoted the success of many unique geometric shapes and novel cutting edge tools. Technological advances in the computer field, such as CAD/CAM software and other design software, have also benefited engineers and tool design engineers in the R&D department. Computer software, finite element analysis systems and simulation software have become the main support and auxiliary tools for R&D engineers to achieve design goals. When optimized for cutting edge geometry, these software can provide the right decision data to further increase machining efficiency and productivity. In this innovative trend, spiral cutting edges have been created that not only reduce energy consumption, but also enable high-intensity machining tasks on low-power machines. At the same time, this innovative trend has also contributed to the development of large positive rake cutting edges, vertical clamping mechanisms and other cost-effective design elements such as multi-edge cutting inserts. The following categories are introduced according to the processing of several new blade: Milling indexable inserts innovative design, advanced geometry and a series of improved tools to enhance the performance of the tool in machining by milling can best embody. From the point of view of mathematical formula calculations, increasing the cutting speed and feed rate plays a key role in milling, as it directly acts to increase the metal removal rate (indicated by Q). Iskar is working to advance the geometrical parameters of the tool and to innovate the shape and design of the cutting edge so that the user can achieve a higher metal removal rate Q. The structure of the milling inserts is changing with each passing day and the evolution is still going on. Improve production efficiency and promote the continuous development of milling concepts. The design points to higher feed rates and direct high metal removal rates. One of the cases, the Isca UFO milling cutter (Feedmill) convex triangular milling insert, large arc cutting edge, has the advantage of high blade feed rate and more material removal per tooth. In addition, the bottom of the insert has a cylindrical raised portion that can be mounted in a matching hole in the sipe, which allows the insert to carry higher cutting forces and operate at ultra-normal feed rates. Based on this design, the clamping of the blade is more secure and the majority of the stress normally acting on the clamping screw is transmitted to the raised portion. Due to the unique geometrical design of the tool, the cutting force acts axially on the spindle, which maintains high stability even in large overhangs. In the second case, in the vertical milling series, the butterfly blade exhibits high chip controllability. The vertical clamping mechanism reduces the stress applied to the screws, thereby eliminating the potential for screw failure. The TANGMILL can achieve high-precision 90° square shoulder milling with a depth of up to 14mm in a single pass. The vertical milling cutter combines a large positive rake cutting edge to reduce cutting forces during machining. In the third case, the Iskal series of milling cutters are round with serrated cutting edges. The bottom of the insert has a cylindrical raised portion that allows the insert to be indexed four times. When performing ultra-deep cavity milling, even if air-cooled blowing is used for chip removal, chip removal often causes problems due to chip shape, weight and size. In deep cavity machining, there is a phenomenon in which the remaining chips are subjected to secondary cutting together. When using a hot wheel blade for machining, due to its unique serrated cutting edge design, the generated chips are small and avoid secondary cutting. In addition, the serrated overlap on the cutting edge of the insert allows for a "full efficiency" tool configuration. Deep cavity large overhanging tools are prone to vibration and instability. In the fourth case, in order to realize the large feed roughing and cavity machining in the mold processing, the HELIDO H600 insert has three mature design concepts: the spiral cutting edge makes the cutting of the tool more stable; the 17° lead angle reduces the tool. Radial force; Susca Tec coating technology extends blade life. Each of the convex triangular blades is ground to form six cutting edges and fastened in the wedge-shaped positioning grooves. The grooving and cutting case five, the advent of the five-pointed tyrant knife. For grooving and cutting, the geometry and shape of the blade evolved from a single-edged, conventional design blade to a pentagonal blade with five cutting edges, each with a chip flute. Therefore, it is economical when performing grooving, cutting and side wall turning. From a geometric point of view, the pentagonal blade has a high radial accuracy due to its thrust stop. This versatile turning tool ensures high precision of the workpiece side wall under large depth of cut and high feed when performing a series of work such as grooving, side wall turning and face turning. This pentagon design gives the blade a stronger reinforcement, resulting in higher cutting parameters, better straightness and surface finish, especially at the bottom and side walls. Case 6, vertical slot cutter, for example, TANG-GRIP vertical self-clamping slot cutter, single head, new clamping method. This design allows the blade to be clamped to the sipe with a high rigidity and the sipe has a longer life. In addition, high straightness and high surface finish can be achieved at high feed rates. For such tools, the cutting force acts on the rear wall of the sipe with a long contact surface and a good rigidity. Compared with the previous clamping system, this new design tool has no upper jaws, so it is more suitable for cutting and interrupting machining of large-diameter workpieces, and the chip removal is smoother. All of these features solve the problem that the blade may fall off when retracting. Conclusion Today, the entire manufacturing industry is striving to increase productivity. More and more manufacturers are actively optimizing the production process and expect to minimize production costs. This relentless pursuit has subverted the design philosophy of traditional tools in terms of shape, geometric parameters and chip flutes. The spiral cutting edge tool born under this innovative trend not only reduces energy consumption, but also enables high-intensity machining tasks on low-power machines. At the same time, this innovative trend has also led to the use of large positive rake cutting edges, vertical clamping mechanisms and other high productivity design elements.