Compact Cutting Insert Geometry for Common Milling Tool Bodies
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Solution Overview
Problem
Existing cutting inserts with stepped parts extending in the diameter direction increase the size, leading to interference issues with common tool bodies, limiting their compatibility with different cutting inserts.
Innovation Solution
A cutting insert design featuring a thickness-reduced surface with a smaller angle than the contact surface, allowing the insert to be compact without protruding radially, enabling use with a common tool body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a stepped part extends in the diameter direction to form a flat contact surface, then the contact surface area is increased, but the cutting insert size increases and causes interference with common tool bodies
Solution Approach 1:
The patent transitions from a radial extension approach (stepped part extending in diameter direction) to an axial approach (thickness-reduced surface extending in axial direction from lower surface). This dimensional change allows the contact surface to be formed without increasing the radial size of the cutting insert, resolving the contradiction between contact surface area and insert size.
Solution Approach 2:
The patent applies different surface characteristics to different regions: the thickness-reduced surface has a smaller angle with the central axis compared to the contact surface, creating a compact profile in the radial direction while maintaining adequate contact surface area. This local differentiation of surface geometry resolves the size conflict.
2Adaptability or versatility
If the edge part is extremely larger than the contact surface, then the contact surface can accommodate various cutting inserts, but the edge parts interfere and the common tool body cannot be used
Solution Approach 1:
The patent forms the contact surface by extending it axially from the lower surface through the thickness-reduced surface, rather than radially. This allows the contact surface to be sufficiently large for various cutting inserts while keeping the radial profile compact to avoid interference with the tool body.
Solution Approach 2:
The patent creates an asymmetric geometry where the thickness-reduced surface has a smaller angle with the central axis than the contact surface. This asymmetric angle configuration allows the contact surface to extend adequately for versatility while the thickness-reduced portion tapers back to prevent radial interference.
Data Source
AI summary
A compact cutting insert that can make tool bodies in common and a milling tool using the cutting insert are provided.The cutting insert (10) has an upper surface (20) and a lower surface (40) on a side opposite to the upper surface (20), and a peripheral side surface (30) that connects the upper surface (20) and the lower surface (40). An edge (11) where the upper surface (20) and the peripheral side surface (30) intersect includes at least one cutting edge (14). The peripheral side surface (30) includes a flank (31) adjacent to the at least one cutting edge (14), a thickness-reduced surface (33) adjacent to the flank (31) from the lower surface (40) side, and a contact surface (32) adjacent to the thickness-reduced surface (33) from the lower surface side. In a section cut out on a plane including a central axis (O), an angle (β) formed by a virtual plane (V) parallel to the central axis (O) passing through a center of the upper surface (20) and a center of the lower surface (40) and passing through the at least one cutting edge (14) and the contact surface (32) is larger than an angle (γ) formed by the virtual plane (V) and the thickness reduced surface (33).