DESC:FIELD OF THE DISCLOSURE

The present disclosure relates to manufacturing of alloy wheels. More particularly, the present disclosure relates to cutting tool assembly for the manufacturing of alloy wheels.

BACKGROUND

Alloy wheels have emerged as a vibrant component used in automobiles. Alloy wheels are lightweight and are aesthetically better than non-alloy wheels, such as steel rims. Manufacturing of alloy wheels involves machining processes for mechanically balanced and aesthetically enchanting alloy wheels. Furthermore, such machining processes include polishing or coating of front face of the alloy wheels that enhances the appearance of the moving wheels when the vehicle is moving.

Various designs on alloy wheels are formed for aesthetic and functional purposes. However, the conventional machining is ineffective and inefficient in furnishing the alloy wheels due to inaccurate fine cutting of the front surface of the alloy wheel. This is because of inadequate tool geometry and material selection. Furthermore, sometimes machining of the alloy wheel requires the use of multiple cutting tools to create serrations on the alloy wheels which causes high manufacturing costs. Also, the frequent tool changes resulting in excessive tool wear result in increased downtime and decreased productivity.

Therefore, in light of the foregoing discussions, there is a need to overcome the limitations/drawbacks of the conventional machining of alloy wheels.

SUMMARY

This summary is provided to introduce a selection of concepts, in a simplified format, that are further described in the detailed description of the invention. This summary is neither intended to identify key or essential inventive concepts of the invention and nor is it intended for determining the scope of the invention.

The present disclosure relates to the manufacturing of alloy wheels. In an embodiment, a cutting tool assembly is disclosed that may include a chuck, a tool post, and a cutting tool. The chuck is adapted to hold a workpiece and rotate the workpiece about a central axis of the chuck. The tool post is slidably mounted on a base and configured to move longitudinally along a first axis of the cutting tool assembly. The tool post having a cutting tool holder configured to move longitudinally and laterally with respect to the workpiece. The cutting tool is installed in the cutting tool holder. The cutting tool may include a shank and a cutting insert.

The shank is adapted to be mounted on the cutting tool holder and the shank may include a top surface, a front surface adjacent to the top surface and having a cut-out portion, and a rear surface adjacent to the top surface and inclined with respect to the top surface to define a clearance angle with a normal axis of the top surface, wherein the clearance angle is in a range from 5 degrees to 10 degrees. The cutting insert is mounted in the cut-out portion of the shank. The cutting insert is having a leading edge of a length in a range from 1mm to 5mm, a trailing edge, a tooltip angle formed through an intersection of the leading edge and the trailing edge in a range from 30 degrees to 40 degrees, and a tool tip radius is in a range from 0.5 mm to 1.0 mm, wherein the cutting insert is adapted to remove material from the workpiece to form a surface of the workpiece having a plurality of serrations.

In another embodiment, a cutting tool is disclosed having a shank and a cutting insert. The shank is having a top surface, a front surface adjacent to the top surface having a cut-out portion, and a rear surface adjacent to the top surface and inclined with respect to the top surface to define a clearance angle with a normal axis of the top surface, wherein the clearance angle is in a range from 5 degrees to 10 degrees.

The cutting insert is mounted in the cut-out portion of the shank. The cutting insert is having a leading edge of a length in a range from 1 mm to 5 mm, a trailing edge, a tooltip angle formed through an intersection of the leading edge, and a trailing edge of the cutting insert in a range from 30 degrees to 40 degrees, and a tool tip radius of the cutting insert is in a range from 0.5 mm to 1.0 mm.

In yet another embodiment, a method of creating a plurality of serrations in a workpiece through a cutting tool assembly is disclosed. The method may include rotating a workpiece mounted on a chuck about a central axis of the chuck at a predetermined speed. The method may also include positioning a cutting tool mounted on a tool post adjacent to an outer peripheral edge of the workpiece. The cutting tool has a shank having a cut-out portion. The cut-out portion accommodates a cutting insert. The cutting insert has a leading edge of a length in a range from 1 mm to 5 mm, a trailing edge, a tooltip angle formed through an intersection of the leading edge, and a trailing edge of the cutting insert in a range from 30 degrees to 40 degrees, and a tool tip radius in a range from 0.5 mm to 1.0 mm.

The method further includes actuating the tool post to bring a tooltip of the cutting tool in contact with a front surface of the workpiece. Also, the method includes moving the cutting tool laterally to the central axis and towards a center of the workpiece at a first feed rate to remove material from a first portion of the workpiece and form a first set of serrations. The method further includes moving the cutting tool laterally to the central axis from the first portion and towards the center of the workpiece at a second feed rate to remove material from a second portion of the workpiece and form a second set of serrations. The method also includes moving the cutting tool laterally to the central axis from the second portion and towards the center of the workpiece at a third feed rate to remove material from a third portion of the workpiece and form a third set of serrations.

According to the present disclosure, the use of the cutting tool with the cutting insert results in improved efficiency in creating serrations in alloy wheels as compared to traditional cutting tools. The predefined parameters of the cutting tool such as the clearance angle, the leading edge, the tool tip radius, and the tooltip angle may lead to greater precision in creating serrations, resulting in a better finish and consistency in the final product. Further, the improved efficiency of the cutting tool reduces the downtime during the manufacturing process, resulting in greater productivity and cost savings. Since there is no requirement to use multiple cutting tools to create serrations, the use of the cutting insert in the cutting tool can lead to more productivity by reducing the need for frequent replacements of multiple cutting tools. Also, the cutting tool is adapted for use with different types of alloy wheels, making the cutting tool a versatile option for the manufacturing industry.

To further clarify advantages and features of the present invention, a more particular description of the invention will be rendered by reference to specific embodiments thereof, which is illustrated in the appended drawings. It is appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of its scope. The invention will be described and explained with additional specificity and detail with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects, and advantages of the present disclosure will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings:

Figure 1 illustrates a block diagram depicting a cutting tool assembly, according to an embodiment of the present disclosure;

Figure 2a illustrates a planar view of a cutting tool installed in a cutting tool holder, according to an embodiment of the present disclosure;

Figure 2b illustrates a perspective view of the cutting tool installed in the cutting tool holder, according to an embodiment of the present disclosure;

Figure 3a illustrates a top view of the cutting tool, according to an embodiment of the present disclosure;

Figure 3b illustrates a side view of the cutting tool, according to an embodiment of the present disclosure;

Figure 3c illustrates a perspective view of the cutting tool, according to an embodiment of the present disclosure;

Figure 4 illustrates exemplary an alloy wheel having a plurality of serrations created by the cutting tool, according to an embodiment of the present disclosure.

Figure 5 illustrates a flow chart of a method for machining alloy wheels, according to an embodiment of the present disclosure; and

Figure 6 illustrates a flow chart of a method of creating a plurality of serrations in a workpiece through the cutting tool assembly, according to an embodiment of the present disclosure.

Further, skilled artisans will appreciate that elements in the drawings are illustrated for simplicity and may not have necessarily been drawn to scale. For example, the flow charts illustrate the method in terms of the most prominent steps involved to help to improve understanding of aspects of the present disclosure. Furthermore, in terms of the construction of the device, one or more components of the device may have been represented in the drawings by conventional symbols, and the drawings may show only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the drawings with details that will be readily apparent to those of ordinary skill in the art having benefit of the description herein.

DETAILED DESCRIPTION OF FIGURES

While the embodiments in the disclosure are subject to various modifications and alternative forms, the specific embodiment thereof has been shown way of example in the figures and will be described below. It should be understood, however, that it is not intended to limit the disclosure to the particular forms disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents, and alternatives falling within the scope of the disclosure.

It is to be noted that a person skilled in the art would be motivated from the present disclosure to modify a cutting tool and a method of creating a plurality of serrations in an alloy wheel through the cutting tool thereof, as disclosed herein. However, such modifications should be construed to be within the scope of the disclosure. Accordingly, the drawings show only those specific details that are pertinent to understand the embodiments of the present disclosure, so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having benefit of the description herein.

Embodiments of the present disclosure will be described below in detail with reference to the accompanying drawings.

For the sake of clarity, the first digit of a reference numeral of each component of the present disclosure is indicative of the Figure number, in which the corresponding component is shown. For example, reference numerals starting with digit “1” are shown at least in Figure 1. Similarly, reference numerals starting with digit “2” are shown at least in Figure 2.

Embodiments of the present disclosure relates to machining of alloy wheels. The present disclosure provides a cutting tool assembly and a method for producing furnished alloy wheels. Furthermore, the cutting tool assembly aids in producing the furnished alloy wheels includes sheer chipping and/or cutting of a front surface or front side of the alloy wheels to achieve glossy or shiny or enchanting front face of the alloys that creates a spiral illusion to the spinning alloy wheels when the vehicle is in motion.

Figure 1 illustrates a block diagram 102 depicting a cutting tool assembly 100, according to an embodiment of the present disclosure. A cutting tool assembly 100 holds a different type or size of cutting tool. The cutting tool assembly 100 includes mechanisms for adjusting the position of the cutting tool and controlling the movement of the cutting tool during machining operations. The cutting tool assembly 100 may be used for cutting and shaping a workpiece 106. The workpiece 106, in one example, can be an alloy wheel 106.

The cutting tool assembly 100 may include a chuck 104. The chuck 104 may be mounted on a spindle (not shown) of the cutting tool assembly 100 and may enable clamping of the workpiece 106 securely in place. The chuck 104 may rotate the workpiece 106 around a central axis A1 of the chuck 104 at a predetermined speed. The predetermined speed is in a range from 500-700 revolutions per minute (RPM), preferably 600 RPM.

The cutting tool assembly 100 includes a tool post 110 that is slidably mounted on a base 112 and may move longitudinally and laterally with respect to the central axis A1 of the cutting tool assembly 100. The tool post 110 may be equipped with a cutting tool holder 108. The cutting tool (shown in Figures 2a and 2b) may be installed in the cutting tool holder 108. The cutting tool (shown in Figures 2a and 2b) may be used to remove material from the workpiece 106 to create a desired shape or a feature in the workpiece 106. In an embodiment, the term "cutting tool holder" may be used interchangeably with "tool post," as the tool post serves as the primary means of holding and positioning cutting tools on the cutting tool assembly 100.

The tool post 110 may allow for a precise movement of the cutting tool (shown in Figures 2a and 2b) along the central axis A1 and with respect to the workpiece 106. This may enable an operator to control a depth and a direction of a cut formed in the workpiece 106. The cutting tool holder 108 may securely hold the cutting tool (shown in Figures 2a and 2b) in place and allows for the necessary movement of the cutting tool (shown in Figures 2a and 2b) to create the desired shape.

The cutting tool assembly 100 may perform a wide range of cutting and shaping operations on various types of workpieces. The cutting tool assembly 100 may allow for precise and efficient machining operations, reducing a need for manual labour and aids in increasing productivity.

Referring to Figures 2a and 2b together. Figure 2a illustrates a planar view of the cutting tool 200 installed in the cutting tool holder 108, according to an embodiment of the present disclosure. Figure 2b illustrates a perspective view of the cutting tool 200 installed in the cutting tool holder 108, according to an embodiment of the present disclosure. The cutting tool 200 may be installed in the cutting tool holder 108 of the tool post 110 through an opening 202. The opening 202 may be designed to allow the cutting tool 200 to be inserted and secured in place within the cutting tool holder 108. The cutting tool 200 may include a shank 204. The shank 204 has the opening 202 for inserting the shank 204 onto the cutting tool holder 108 with a tooltip 206 of the cutting tool 200 protruding out of the cutting tool holder 108 for engagement with the workpiece 106.

Once the cutting tool 200 is properly secured in the cutting tool holder 108, the cutting tool 200 may be moved longitudinally and laterally with respect to the workpiece 106. This allows for precise and controlled removal of material from the workpiece 106 creating the desired shape or feature.

The cutting tool 200 may be adjusted to a particular height, angle, and position with the help of the cutting tool holder 108 to achieve the desired cut on the workpiece 106. The cutting tool holder 108 is designed to allow for easy adjustment of the cutting tool 200 as needed during operation so that the tool 200 can be repositioned or replaced quickly and easily. The ability to adjust a position, an angle, and a feed rate of the cutting tool 200 allows for a high degree of precision in the manufacturing process.

Referring to Figures 3a-3c together, Figure 3a illustrates a top view of the cutting tool 200, according to an embodiment of the present disclosure. Further, Figure 3b illustrates a side view of the cutting tool 200, and Figure 3c illustrates a perspective view of the cutting tool 200.

The cutting tool 200 includes the shank 204 and a cutting insert 300. The shank 204 may be mounted on the cutting tool holder 108. The shank has a top surface T, a front surface F adjacent to the top surface T, and a rear surface R adjacent to the top surface T. The front surface F has a cut-out portion 302. The rear surface R is inclined with respect to the top surface T, defining a clearance angle C with a normal axis of the top surface T. The clearance angle C is in a range from 5 degrees to 10 degrees. The shank may be made up of a carbide material.

The cutting insert 300 may be mounted in the cut-out portion 302 of the shank 204. Further, the cutting insert 300 may have a leading edge LE, a trailing edge TE, a tooltip angle A, and a tool tip radius R. The leading edge LE may have a length in a range from 1 mm to 5 mm, preferably 5 mm. The tooltip angle A may be formed through an intersection of the leading edge LE and the trailing edge TE and is in a range from 30 degrees to 40 degrees, preferably 35 degree. The tool tip radius R may be in a range from 0.5 mm to 1.0 mm, preferably 0.8 mm.

The cutting insert 300 is adapted to remove material from the workpiece 106 to form a surface of the workpiece 106 having a plurality of serrations (shown in figure 6). The cutting insert 300 is designed to provide smooth and precise cuts, minimizing the need for additional finishing steps.

Further, the cutting insert 300 may be but is not limed to, triangular in shape. The cutting insert 300 is made up of a polycrystalline diamond (PCD). PCD is a synthetic material composed of diamond particles that have been sintered together under high pressure and temperature. PCD is extremely hard and durable, making it an ideal material for cutting tools. The use of PCD ensures that the leading edge stay sharp for longer periods of time compared to traditional cutting materials like carbide.

The cutting tool assembly 100 with the cutting insert 300 made of PCD may maintain a high level of cutting performance over an extended period of time, reducing the need for frequent tool changes and increasing productivity. Additionally, the use of PCD in the cutting insert 300 may reduce the amount of heat generated during cutting which can help to prolong the life of the cutting tool 200 and improve the quality of finishing provided to the workpiece 106.

Figure 4 illustrates exemplary the alloy wheel 106 having the plurality of serrations 402 created by the cutting tool 200, according to an embodiment of the present disclosure.

The type of plurality of serrations 402 that may be provided on the alloy wheel 106 using the cutting tool assembly 100 may vary based on a specific design and requirements of the alloy wheel 106. Generally, the plurality of serrations 402 may be provided in various shapes, sizes, and patterns to achieve different functional and aesthetic effects. In one example, the plurality of serrations 402 may be provided in a radial or a circumferential pattern, or in a combination of both. The plurality of serrations 402 may also be provided in a zig-zag pattern or a wave pattern, among others.

The depth and spacing of the plurality of serrations 402 may also be adjusted to achieve different effects. The cutting tool assembly 100 may provide a high level of control and precision in the formation of the plurality of serrations 402, allowing for a wide range of designs to be achieved. In the present disclosure, the plurality of serration 402 may either be spiral serrations or concentric serrations, preferably concentric serrations.

Details on the manufacturing of the alloy wheel 106 are explained with respect to Figures 5 and 6. Specifically, Figure 5 illustrates a flow chart of a method 500 for machining alloy wheels 106, according to an embodiment of the present disclosure. The method 500 includes the preparation of an alloy wheel 106 structure and thereby machining the alloy wheel 106 structure to produce a finished product as a furnished alloy wheel 106. According to the present disclosure, the method 500 includes steps, without limiting the scope of the invention, to manufacture the furnished alloy wheels 106.

At a step 502, an alloy wheel 106 structure is casted from metallic ores. The metallic ores are collected and mixed with binders to prepare a sinter that is stored for heating. The mixed metal ore (sinter) is heated to a melting point to melt and obtain molten alloy. Furthermore, the molten alloy is poured into a mould to undergo gravity die casting to prepare the metal alloy structure. Moreover, the metal alloy wheel 106 structure is prepared as per requirement and is in a rough shape that includes a thickness relatively greater than the finished one to have machining allowances. In an embodiment, the casted metal alloy wheel 106 structure is heat treated (solutionising) to form a regular shape and/or uniform shape of the metal alloy wheel 106 structure.

At a step 504, the casted alloy wheel 106 structure is cut using a gate cutting technique. The casted alloy wheel 106 structure undergoes gate cutting to cut off internal sections of the alloy wheel 106 structure to form a desired shape and size of the alloy wheel 106 structure. In further processes, the alloy wheel 106 structure is heat treated (aging) to smoothen the cuts and edges of the alloy wheel 106 structure. Moreover, the alloy wheel 106 structure is shot blasted and visually inspected to ensure precision of the alloy wheel 106 structure.

At a step 506, the alloy wheel 106 structure is machined to remove uneven surfaces. In further processes, the alloy wheel 106 structure undergoes a machining process to chip off the unwanted materials and elevated surfaces from the alloy wheel 106 structure. Furthermore, the alloy wheel 106 structure is tested to ensure no leakage and/or porosity in a grain structure of the alloy wheel 106 structure.

At a step 508, the alloy wheel 106 structure is balanced to assume a stable and levelled alignment when employed in vehicles. Furthermore, the alloy wheel 106 structure is punched and hammered to balance and attain a balanced shape to be employed in vehicles. Moreover, the alloy wheel 106 structure is inspected to ensure a balance and/or alignment of the alloy wheel 106 structure.

At a step 510, the alloy wheel 106 structure is furnished using diamond cutting to obtain chrome-finished alloy wheel 106. Furthermore, the alloy wheel 106 structure is heat treated when moved from balancing to the diamond cutting. The alloy wheel 106 structure is coated and baked prior to diamond cutting. The coating is performed using powder coating and liquid coating of paints and adhesives.

At a step 512, coating the alloy wheel 106 with primers and paints. Furthermore, the diamond cut alloy wheel 106 is further coated with primers and liquid coating to obtain finished alloy wheel 106s.

At a step 514, the alloy wheel 106 is inspected to be stored in a finished goods warehouse. Furthermore, the alloy wheel 106 is finally inspected under precision tests to achieve a furnished alloy wheel 106. The furnished alloy wheel 106 are stored in a warehouse.

Details of the step 510 is now explained with respect to Figure 6 that illustrates a method 600 of creating the plurality of serrations 402 in the workpiece 106 through the cutting tool assembly 100, according to an embodiment of the present disclosure.

At step 602, the workpiece 106 may be mounted on the chuck 104. The workpiece 106 may be clamped securely on the chuck 104 to ensure that the workpiece 106 doesn't move out or vibrate during the cutting process. The workpiece 106 is then rotated at the predetermined speed around the central axis A1 of the chuck 104. The predetermined speed may be selected based on a type of workpiece 106 being cut or a desired finish quality. In an exemplary embodiment, the predetermined speed in the present disclosure is in the range of 500 to 700 RPM, preferably 600 RPM.

At step 604, the cutting tool 200 mounted on the cutting tool holder 108 is positioned adjacent to an outer peripheral edge of the workpiece 106. The cutting tool 200 includes the shank 204 having the cut-out portion 302 to accommodate the cutting insert 300. The cutting insert 300 may have the leading edge LE in a range from 1 mm to 5 mm, the trailing edge TE, the tooltip angle A formed through the intersection of the leading edge LE and the trailing edge TE in the range from 30 degrees to 40 degrees, and the tool tip radius R in the range from 0.5 mm to 1.0 mm. The cutting tool 200 is positioned precisely to ensure that the plurality of serrations 402 are formed accurately and uniformly.

At step 606, the cutting tool holder 108 may be actuated to bring the tool tip 206 of the cutting tool 200 in contact with the front surface of the workpiece 106. The cutting tool 200 is brought closer to the workpiece 106 until the tooltip 206 touches the front surface of the workpiece 106.

At step 608, the cutting tool 200 may be moved laterally towards the central axis A1 of the chuck 104 from the outer periphery of the workpiece 106. The cutting tool 200 is moved towards a centre of the workpiece 106 at a first feed rate to remove material from a first portion of the workpiece 106 and form a first set of serrations 402a. The first feed rate is selected based on the desired depth and width of the first set of serrations 402a and the material characteristics of the workpiece 106. In an exemplary embodiment, the first feed rate is 6 mm/rev.

At step 610, after the first set of serrations 402a are formed, the cutting tool 200 may move laterally towards the central axis A1 of the chuck 104 from the first portion. The cutting tool 200 moves towards the centre of the workpiece 106 at a second feed rate to remove material from a second portion of the workpiece 106 and form a second set of serrations 402b. The second feed rate may be different from the first feed rate depending on the desired depth and width of the second set of serrations 402b. In an exemplary embodiment, the second feed rate is 4 mm/rev.

At step 612, the cutting tool 200 is moved laterally towards the central axis A1 of the chuck 104 from the second portion and towards the centre of the workpiece 106 at a third feed rate to remove material from a third portion of the workpiece 106 and form a third set of serrations 402c. The third feed rate may be different from the first feed rate and second feed rate depending on the desired depth and width of the third set of serrations 402c. In an exemplary embodiment, the third feed rate is 2 mm/rev.

In an embodiment, the feed rate of the cutting tool 200 is based on revolutions per minute (RPM) of the workpiece 106 such that the feed rate and the RPM are inversely proportional to each other.

The method 600 involves a precise and controlled cutting process to create the plurality of serrations 402 on the workpiece 106 using the cutting tool assembly 100. The method 600 may be repeated multiple times to create a large number of serrations on the workpiece 106, as needed.

The workpiece 106 may be the alloy wheel. The plurality of serrations 402 provides better heat dissipation due to an increased surface area created on the alloy wheel 106. The plurality of serrations 402 may include either the spiral serrations or the concentric serrations, preferably concentric serrations.

Embodiments of the present disclosure provide a machined and polished front surface of the alloy wheel 106 that enhances an appearance of spinning wheels when the vehicle is in motion.

Furthermore, the cutting tool 200 with the cutting insert 300 results in improved efficiency while creating the plurality of serrations 402 in alloy wheel 106 as compared to traditional cutting tools. The predefined parameters of the cutting tool 200 such as the clearance angle, the leading edge, the tool tip radius, and the tooltip angle may lead to greater precision in creating the plurality of serrations 402, resulting in a better finish and consistency in the final product. Further, the improved efficiency of the cutting tool 200 reduces the downtime during the manufacturing process, resulting in greater productivity and cost savings. Since there is no requirement to use multiple cutting tools to create the plurality of serrations 402, the use of the cutting insert 300 in the cutting tool 200 can lead to more productivity by reducing the need for frequent replacements of multiple cutting tools. Also, the cutting tool 200 is adapted for use with different types of alloy wheels 106, making it a versatile option for the manufacturing industry.

While specific language has been used to describe the present disclosure, any limitations arising on account thereto, are not intended. As would be apparent to a person in the art, various working modifications may be made to the method in order to implement the inventive concept as taught herein. The drawings and the foregoing description give examples of embodiments. Those skilled in the art will appreciate that one or more of the described elements may well be combined into a single functional element. Alternatively, certain elements may be split into multiple functional elements. Elements from one embodiment may be added to another embodiment.
,CLAIMS:1. A cutting tool assembly (100) comprising:
a chuck (104) adapted to hold a workpiece (106) and rotate the workpiece (106) about a central axis (A1) of the chuck (104);
a tool post (110) slidably mounted on a base (112) and configured to move longitudinally and laterally with respect to the central axis (A1) of the cutting tool assembly (100), the tool post (110) having a cutting tool holder (108) configured to move longitudinally and laterally with respect to the workpiece (106);
a cutting tool (200) installed in the cutting tool holder (108), comprising:
a shank (204) adapted to be mounted on the cutting tool holder (108), the shank (204) having:
a top surface (T);
a front surface (F) adjacent to the top surface (T) and having a cut-out portion (302); and
a rear surface (R) adjacent to the top surface (T) and inclined with respect to the top surface (T) to define a clearance angle (C) with a normal axis of the top surface (T), wherein the clearance angle (C) is in a range from 5 degrees to 10 degrees; and
a cutting insert (300) mounted in the cut-out portion (302) of the shank (204), the cutting insert (300) having a leading edge (LE) of a length in a range from 1mm to 5mm, a trailing edge (TE), a tooltip angle (A) formed through an intersection of the leading edge (LE) and the trailing edge (TE) is in a range from 30 degrees to 40 degrees, and a tool tip radius (R) is in a range from 0.5 mm to 1.0 mm,
wherein the cutting insert (300) is adapted to remove material from the workpiece (106) to form a surface of the workpiece (106) having a plurality of serrations (402).

2. The cutting tool assembly (100) as claimed in claim 1, wherein the cutting insert (300) is triangular and is made up of a polycrystalline diamond.

3. The cutting tool assembly (100) as claimed in claim 1, wherein the shank (204) is made up of a carbide material.

4. The cutting tool assembly (100) as claimed in claim 1, wherein a feed rate of the cutting tool (200) is between 2 mm/rev and 6 mm/rev, and the feed rate of the cutting tool (200) is based on revolutions per minute (RPM) of the workpiece (106) such that the feed rate and the RPM are inversely proportional to each other.

5. The cutting tool assembly (100) as claimed in claim 1, wherein the plurality of serrations (402) includes one of spiral serrations and concentric serrations.

6. A cutting tool (200) comprising:
a shank (204) having:
a top surface (T);
a front surface (F) adjacent to the top surface (T) having a cut-out portion (302); and
a rear surface (R) adjacent to the top surface (T) and inclined with respect to the top surface (T) to define a clearance angle (C) with a normal axis of the top surface (T), wherein the clearance angle (C) is in a range from 5 degrees to 10 degrees; and
a cutting insert (300) mounted in the cut-out portion (302) of the shank (204), the cutting insert (300) having:
a leading edge (LE) of a length in a range from 1 mm to 5 mm;
a trailing edge (TE);
a tooltip angle (A) formed through an intersection of the leading edge (LE) and a trailing edge (TE) of the cutting insert (300) is in a range from 30 degrees to 40 degrees; and
a tool tip radius (R) of the cutting insert (300) is in a range from 0.5 mm to 1.0 mm.

7. The cutting tool (200) as claimed in claim 6, wherein the cutting insert (300) is triangular and made up of a polycrystalline diamond.

8. The cutting tool (200) as claimed in claim 6, wherein the shank (204) is made up of a carbide material.

9. A method (600) of creating a plurality of serrations (402) in a workpiece (106) through a cutting tool assembly (100), the method (600) comprising the steps of:
rotating a workpiece (106) mounted on a chuck (104) about a central axis (A1) of the chuck (204) at a predetermined speed;
positioning a cutting tool (200) mounted on a cutting tool holder (108) adjacent to an outer peripheral edge of the workpiece (106), wherein the cutting tool (200) has a shank (204) having a cut-out portion (302) to accommodate a cutting insert (300) and the cutting insert (300) having a leading edge (LE) of a length in a range from 1 mm to 5 mm, a trailing edge (TE), a tooltip angle (A) formed through an intersection of the leading edge (LE) and a trailing edge (TE) of the cutting insert (300) is in a range from 30 degrees to 40 degrees, and a tool tip radius (R) in a range from 0.5 mm to 1.0 mm;
actuating the cutting tool holder (108) to bring a tooltip (206) of the cutting tool (200) in contact with a front surface of the workpiece (106);
moving the cutting tool (200) laterally to the central axis (A1) and towards a center of the workpiece (106) at a first feed rate to remove material from a first portion of the workpiece (106) and form a first set of serrations (402a);
moving the cutting tool (200) laterally to the central axis (A1) from the first portion and towards the center of the workpiece (106) at a second feed rate to remove material from a second portion of the workpiece (106) and form a second set of serrations (402b); and
moving the cutting tool (200) laterally to the central axis (A1) from the second portion and towards the center of the workpiece (106) at a third feed rate to remove material from a third portion of the workpiece (106) and form a third set of serrations (402c).

10. The method (600) as claimed in claim 9, wherein the predetermined speed is in a range from 500-700 revolutions per minute (RPM) and a feed rate of the cutting tool (200) is based on the RPM of the workpiece (106) such that the feed rate and RPM are inversely proportional to each other.

11. The method (600) as claimed in claim 9, wherein the first feed rate is 6 mm/rev, the second feed rate is 4 mm/rev, and the third feed rate is 2 mm/rev.

12. The method (600) as claimed in claim 9, wherein the shank (204) having a top surface (T), a front surface (F) adjacent to the top surface (T) having the cut-out portion (302), and a rear surface (R) adjacent to the top surface (T) and inclined with respect to the top surface (T) to define a clearance angle (C) with a normal axis of the top surface (T), wherein the clearance angle (C) is in a range from 5 degrees to 10 degrees.

13. The method (600) as claimed in claim 9, wherein the cutting tool assembly (100) comprising, the chuck (104) adapted to hold and rotate the workpiece (106), and the tool post (110) adapted to mount and move the cutting tool (200) longitudinally and laterally with respect to the workpiece (106).