Asymmetric Cutting Insert Geometry for Clamp Stability and Chip Flow
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Solution Overview
Problem
Existing cutting inserts face challenges with clamping force, insert strength, and chip dischargeability, particularly when subjected to rotating forces and large loads, leading to potential defects and deformation during processing.
Innovation Solution
A cutting insert design with a smaller major cutting edge angle than the constraining surface angle, featuring a convex R region between the major and inner cutting edges, and strategically positioned cutting edges to reduce cutting resistance and enhance chip dischargeability, while maintaining compatibility with conventional tool bodies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the constraining surface is inclined away from the center axis to improve clamping performance, then the clamp performance is improved, but the insert may rotate under cutting forces
Solution Approach 1:
The patent applies asymmetry by making the angle of the major cutting edge smaller than the angle of the constraining surface in top view. This asymmetric angular relationship creates a geometric interlocking effect where the cutting edge engages the workpiece at a sharper angle while the constraining surface maintains a larger angle for stable clamping, preventing insert rotation under cutting forces
Solution Approach 2:
The patent changes the angular parameters of the cutting edge and constraining surface independently. By optimizing the major cutting edge angle to be smaller than the constraining surface angle, the patent achieves both effective cutting engagement and stable clamping, resolving the contradiction between clamping force and insert stability
2Force
If the cutting angle is reduced to decrease cutting resistance, then the cutting resistance decreases, but the insert strength and chip dischargeability must be maintained
Solution Approach 1:
The patent optimizes the cutting angle parameter by making the major cutting edge angle smaller than the constraining surface angle. This parameter change reduces cutting resistance while the patent simultaneously maintains insert strength through proper geometric design of the cutting edges and chip dischargeability through the R region configuration
3Productivity
If the cutting angle is reduced to improve chip dischargeability, then the chip dischargeability improves, but the insert must maintain sufficient strength
Solution Approach 1:
The patent introduces an R region with a convex shape between the major cutting edge and the inner cutting edge. This curved geometric feature improves chip dischargeability by facilitating chip flow while the overall insert geometry maintains sufficient strength to handle cutting forces
Data Source
AI summary
Provided is a cutting insert and a cutting tool equipped with the cutting tool improving the force to clamp the insert and improving the strength of the insert and the chip dischargeability. The cutting insert includes: an upper surface, which is a first end surface; a lower surface, which is a surface on an opposite side to the upper surface, and is a second end surface having an installing surface for installing a cutting tool; a screw hole which has an axial line penetrating from the upper surface to the lower surface; a peripheral side surface which is formed such that the upper surface and the lower surface are connected; a major cutting edge and an inner cutting edge which are formed in an intersecting region between the upper surface and the peripheral side surface, and an intersecting region between the lower surface and the peripheral side surface, respectively; and a constraining surface which is formed on the peripheral side surface so as to at least partially contact with a body. An angle of the major cutting edge and an angle of the constraining surface are different in a top view viewed from the upper surface, and the angle of the major cutting edge is smaller than the angle of the constraining surface.