Asymmetric Cutting Insert Angles for Clamping Stability
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Solution Overview
Problem
Existing cutting inserts face challenges with clamping force, insert strength, and chip dischargeability, particularly when subjected to rotational forces and large cutting angles, which can lead to defects and deformation during processing.
Innovation Solution
A cutting insert design featuring a smaller angle for the major cutting edge compared to the constraining surface, along with a convex R portion and differing angles for the major and inner cutting edges, reduces cutting resistance and improves chip dischargeability by altering the cutting angle and distributing cutting forces effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the angle of the major cutting edge is made smaller than the angle of the constraining surface, then the cutting resistance decreases and the force to rotate the cutting insert decreases, but the clamping performance and insert strength must be maintained
Solution Approach 1:
The patent applies asymmetry by making the angle of the major cutting edge (α) different from the angle of the constraining surface (β), specifically setting α < β. This asymmetric angular configuration optimizes the cutting geometry to reduce cutting resistance and rotational force while the constraining surface maintains adequate clamping performance through its larger angle.
2Productivity
If the cutting angle of the cutting insert is decreased, then the thickness of chips decreases and feeding increases, but the insert strength must be maintained
Solution Approach 1:
The patent changes the geometric parameters of the cutting insert, specifically the cutting angle formed by the major cutting edge. By optimizing this angle to be smaller than the constraining surface angle, the patent achieves thinner chip thickness and increased feeding capability while maintaining insert strength through proper geometric configuration.
3Force
If the angle of the major cutting edge is made smaller than the angle of the constraining surface, then the force to rotate the cutting insert decreases, but the clamping force must be sufficient to prevent insert defects
Solution Approach 1:
The asymmetric angular relationship between the major cutting edge and constraining surface creates an optimal balance where the cutting edge angle is smaller to reduce rotational force, while the constraining surface angle is larger to provide sufficient clamping force and prevent insert defects during operation.
Data Source
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AI summary
Provided is a cutting insert (10) and a cutting tool (100) 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 (21) and an inner cutting edge (22) 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 (40) 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.