Obtaining Various Shapes of Machined Surface Using a Tool with a Multi-Insert Cutting Edge

Abstract

A novel design of a universal form tool is presented for machining complex planar and axisymmetric surfaces. The geometric and kinematic flexibility (GKF) of this tool type means that it can machine a wide range of profiles using a single setup. The operating principle of this multi-insert tool is its combination of single cutting edges, each of which form the individual details of the machined surface. The structure and application of both turning and milling multi-insert tools with combinations of single edges are described in the paper. Complex shapes and forms can be machined by changing the cutting-edge positions. The number of combinations of a given tool set can be determined by using the relations detailed in this study. Both turning and milling tools are utilized in a unique tool holder that clamps the inserts into position and allows their adjustment that is facilitated by special prepared analytical software to the desired object profiles. It is possible to use these tools in machining both wood and aluminum alloys. Finally, the design of the multi-insert tools for turning and milling and its functional features were experimentally verified with positive results.