Double-Sided Circular Cutting Insert With Wedge Clamping Stability
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Solution Overview
Problem
R-type indexible cutting inserts are vulnerable to rotation under cutting loads, leading to decreased fastening force, abrasion, vibration, and sudden breakage, especially in double-sided types, which compromises tool stability and life.
Innovation Solution
A circular double-sided cutting insert with multiple fastening surfaces forming acute angles with respect to the top and bottom surfaces, featuring a wedge-shaped configuration and specific geometric arrangements to ensure uniform fastening force, including a transition section between fastening and clearance surfaces, and inclined major cutting edges to minimize material removal and maintain rigidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a circular double-sided cutting insert is used to improve economic feasibility, then cost efficiency is improved, but the insert becomes vulnerable to rotation under cutting loads causing decreased fastening force and tool instability
Solution Approach 1:
The lateral surface is segmented into multiple fastening surfaces (at least three) and clearance surfaces, where fastening surfaces are positioned at specific angular intervals to provide distributed fastening points that resist rotational forces while maintaining structural integrity
Solution Approach 2:
Different regions of the lateral surface are given different properties: fastening surfaces have specific angular orientations and geometries optimized for fastening force distribution, while clearance surfaces provide necessary clearance. This local differentiation allows the insert to maintain stability under cutting loads while preserving economic feasibility through double-sided usage
2Productivity
If the cutting insert is rotated during cutting to extend usage, then productivity is improved, but the seating part suffers abrasion and fastening force decreases leading to vibration and breakage
Solution Approach 1:
Multiple fastening surfaces are distributed around the lateral surface at specific angular intervals, creating multiple stable seating positions. This segmentation allows the insert to be indexed to different orientations without compromising fastening force, enabling tool life extension through rotation while maintaining reliability
Solution Approach 2:
The fastening surfaces are designed to work collectively with the tool holder seating part, distributing the fastening force across multiple contact points. This merging of multiple fastening functions into a unified structure allows the insert to maintain stable fastening force even when rotated to different positions for extended usage
Data Source
AI summary
A cutting insert according to an embodiment of the present disclosure relates to a circular double-sided cutting insert including a top surface, a bottom surface, a lateral surface, and a cutting edge, and mounted to a cutting tool, in which a plurality of clearance surfaces and a plurality of fastening surfaces are located on the lateral surface, and among the plurality of fastening surfaces, a fastening surface, which is brought into contact with the cutting tool upon mounting of the cutting insert to the cutting tool, forms an acute angle with respect to the top surface or the bottom surface acting as a rake surface.