Robust Design Framework for Cutting Tool Interface Design
Doctoral thesis, 2025
Failure to maintain an even pressure distribution and robustness in the positioning
of inserts in indexable cutting tools can often result in critical failures
during machining, such as increased wear and clamp screw fatigue, leading to
costly design reiterations. Current locating schemes do not consider aspects
such as external loads and non-linear material models, which are crucial to
consider in indexable cutting tools as the loads acting on the insert and tool
body often exceed the yield limit of materials. Therefore, this thesis proposes
a framework with methodologies to assist engineers in the early design phases
of indexable cutting tools to develop a robust positioning of the insert with
the tool body interface. The framework focuses on optimizing the positioning
of the insert, ensuring that the tool performs effectively under operational
loads. By incorporating techniques such as Finite Element Analysis (FEA),
genetic algorithms, stability analysis, and contact index optimization, the framework
enables engineers to address key challenges like pressure distribution,
insert movement, and fatigue, ultimately enhancing cutting tools’ durability,
reliability, and performance.
Applying the proposed framework to the existing insert design, R390-
11T308M-MM2030 created a first-iteration prototype of the tool body interface.
The prototype exhibited enhanced durability and reliability, ensuring more
robust insert positioning under operational loads. The prototype maintained
comparable efficiency to its predecessor and did not compromise the tool’s
overall productivity. This advancement suggests that further refinements could
enhance the prototype’s overall effectiveness, potentially leading to even more
significant improvements in future iterations.
of inserts in indexable cutting tools can often result in critical failures
during machining, such as increased wear and clamp screw fatigue, leading to
costly design reiterations. Current locating schemes do not consider aspects
such as external loads and non-linear material models, which are crucial to
consider in indexable cutting tools as the loads acting on the insert and tool
body often exceed the yield limit of materials. Therefore, this thesis proposes
a framework with methodologies to assist engineers in the early design phases
of indexable cutting tools to develop a robust positioning of the insert with
the tool body interface. The framework focuses on optimizing the positioning
of the insert, ensuring that the tool performs effectively under operational
loads. By incorporating techniques such as Finite Element Analysis (FEA),
genetic algorithms, stability analysis, and contact index optimization, the framework
enables engineers to address key challenges like pressure distribution,
insert movement, and fatigue, ultimately enhancing cutting tools’ durability,
reliability, and performance.
Applying the proposed framework to the existing insert design, R390-
11T308M-MM2030 created a first-iteration prototype of the tool body interface.
The prototype exhibited enhanced durability and reliability, ensuring more
robust insert positioning under operational loads. The prototype maintained
comparable efficiency to its predecessor and did not compromise the tool’s
overall productivity. This advancement suggests that further refinements could
enhance the prototype’s overall effectiveness, potentially leading to even more
significant improvements in future iterations.
Robust Design
Data-Driven Engineering
Computer Aided Design
Cutting Tool Interface Design
Variation Simulation
Geometry Assurance
Computer Aided Engineering
Virtual Development Lab (VDL), Hörsalsvägen 7A
Opponent: Prof. Andreas Archenti, Department of Production Engineering, KTH Royal Institute of Technology, Sweden
Author
Soner Camuz
Chalmers, Industrial and Materials Science, Product Development
In manufacturing, precision is everything, especially when it comes to the cutting tools used in machines. These tools often rely on small, replaceable parts called inserts that do the actual cutting. But if those inserts aren’t held in place properly, things can go wrong: they wear out faster, screws that hold them can break, and engineers may have to redesign the tool altogether.
One big problem is that current designs don’t always consider how real-world forces affect the tool during cutting. These forces can be strong enough to push materials past their limits, and if the insert isn't seated perfectly, it can move or even fail.
This research introduces a new approach to designing these tools. It gives engineers a set of methods they can use early in the design process to make sure inserts are positioned in a way that can handle the pressure. Using advanced simulations, smart algorithms, and engineering analysis, the new framework helps improve how the insert fits with the rest of the tool. The result? Tools that are tougher, more reliable, and perform better under pressure.
To test the idea, the framework was applied to a real cutting tool insert called R390-11T308M-MM2030. The redesigned version showed clear improvements: the insert stayed firmly in place during use and the tool lasted longer, without sacrificing performance. And since this was just a first version, there’s room for even more improvement in the future.
One big problem is that current designs don’t always consider how real-world forces affect the tool during cutting. These forces can be strong enough to push materials past their limits, and if the insert isn't seated perfectly, it can move or even fail.
This research introduces a new approach to designing these tools. It gives engineers a set of methods they can use early in the design process to make sure inserts are positioned in a way that can handle the pressure. Using advanced simulations, smart algorithms, and engineering analysis, the new framework helps improve how the insert fits with the rest of the tool. The result? Tools that are tougher, more reliable, and perform better under pressure.
To test the idea, the framework was applied to a real cutting tool insert called R390-11T308M-MM2030. The redesigned version showed clear improvements: the insert stayed firmly in place during use and the tool lasted longer, without sacrificing performance. And since this was just a first version, there’s room for even more improvement in the future.
Subject Categories (SSIF 2025)
Mechanical Engineering
ISBN
978-91-8103-168-3
Doktorsavhandlingar vid Chalmers tekniska högskola. Ny serie: 5626
Publisher
Chalmers
Virtual Development Lab (VDL), Hörsalsvägen 7A
Opponent: Prof. Andreas Archenti, Department of Production Engineering, KTH Royal Institute of Technology, Sweden