Asymmetric Cutting Insert Geometry for Deep-Cut Face Milling
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Solution Overview
Problem
Existing cutting tools are inadequate for deep cuts due to small cutting edge angles and limited axial rake angles, making them unsuitable for efficient processing of materials.
Innovation Solution
A cutting insert with a decagonal shape and alternating internal angles on its end surfaces, featuring a major and minor cutting edge configuration that allows for a positive axial rake angle and large cutting edge angle, enabling effective deep cutting operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a conventional cutting insert with small cutting edge angle is used for high feeding cutter, then the cutting tool can perform high feeding operations, but the cutting insert is inappropriate for deep cutting due to limited axial rake angle
Solution Approach 1:
The cutting insert employs asymmetric corner design with alternating internal angles (first corner with smaller internal angle, second corner with larger internal angle). This asymmetry creates different flank surface orientations that enable both high feeding rate and positive axial rake angle for deep cutting operations
Solution Approach 2:
The invention introduces a new geometric dimension by creating uplifted portions on the rake surface through the alternating corner angle design. This dimensional change allows the cutting insert to achieve positive axial rake angle while maintaining the high feeding capability, effectively adding a new degree of freedom to the cutting geometry
2Ease of manufacture
If a negative type cutting insert with right angle between end surface and peripheral surface is used for face mill, then the cutting insert can perform plane processing, but the axial rake angle is limited and inappropriate for making deep cuts
Solution Approach 1:
The cutting insert employs asymmetric corner design with alternating internal angles (first corner with smaller internal angle, second corner with larger internal angle). This asymmetry creates different flank surface orientations that enable both high feeding rate and positive axial rake angle for deep cutting operations
Solution Approach 2:
The invention changes the geometric parameters of the cutting insert by creating alternating internal angles at corners and corresponding uplifted portions on rake surfaces. This parameter modification transforms the conventional right-angle geometry into a configuration that provides both plane processing capability and positive axial rake angle for deep cutting
Data Source
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AI summary
A cutting insert (10) according to an aspect of the present invention is provided with a plurality of cutting portions (18) formed at the intersection portion of each end surface (12, 14) and a peripheral surface (16). Each cutting portion includes a first cutting edge (18a) and a second cutting edge (18b). In an end surface view, first corners (20) and second corners (22) which differ in their internal angles are alternately formed in each end surface. An internal angle α of the first corner (20) is smaller than an internal angle β of the second corner (22, 122, 222). Each first cutting edge (18a) has a portion extending to approach the median plane M as a distance from a corresponding first corner (20) increases. A first side surface portion (30a) extending on the peripheral surface from each first cutting edge forms an insert internal obtuse angle to a plane passing through the first cutting edge and being in parallel to the median plane M, and a second side surface portion (30b) extending on the peripheral surface from each second cutting edge forms an insert internal acute angle to a plane passing through the second cutting edge and being in parallel to the median plane M.