Convex Cutting Edge Geometry for High Feed Rate Inserts
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Solution Overview
Problem
Conventional double-sided cutting inserts with straight line-shaped main and sub cutting edges suffer from decreased edge strength and are unsuitable for high feed rate cutting due to significant contact load with the workpiece.
Innovation Solution
A double-sided cutting insert design featuring outwardly convex shorter cutting edges, longer cutting edges with concave sections, and symmetrical corner cutting edges, which enhance edge strength and reduce contact resistance, allowing for high feed rate cutting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If straight line-shaped main and sub cutting edges are used, then the cutting insert structure is simple, but the edge strength is decreased and contact load is high
Solution Approach 1:
The patent applies curvature to the cutting edges by forming the main cutting edge as an arc rather than a straight line, and designing the sub cutting edge with a specific curved profile. This curvature increases the edge strength by distributing stresses more effectively while reducing contact load with the workpiece, directly resolving the contradiction between simple geometry and sufficient strength.
2Ease of manufacture
If straight line-shaped cutting edges are used, then manufacturing is easier, but the cutting insert cannot be used for high feed rate cutting due to high contact load
Solution Approach 1:
The curved main cutting edge and specifically profiled sub cutting edge reduce the contact area and contact load with the workpiece during cutting. This geometric optimization enables the cutting insert to withstand higher feed rates without excessive contact forces, thereby improving productivity while remaining manufacturable through standard ceramic forming processes.
3Device complexity
If conventional cutting edge shapes are used, then the cutting insert structure is simple, but considerable contact load prevents high feed rate cutting
Solution Approach 1:
The arc-shaped main cutting edge and curved sub cutting edge profile reduce the line contact with the workpiece to a more distributed contact pattern. This curvature geometry decreases the concentrated contact load while maintaining structural simplicity, enabling high feed rate cutting operations.
Solution Approach 2:
The patent applies different geometric characteristics to different parts of the cutting insert: the main cutting edge has a specific arc radius for optimal cutting performance, while the sub cutting edge has a different curved profile for chip control and load distribution. This localized geometric optimization reduces overall contact load while maintaining simplicity in the overall structure.
Data Source
AI summary
The technical objective of the present invention is to provide a double-sided cutting insert having a high feed rate, which can increase the edge strength and reduce the cutting load, and thus can be suitable for high feed rate processing. To this end, a double-sided cutting insert having a high feed rate according to the present invention comprises: two main surfaces that face in opposite directions; two shorter side surfaces, which connect between the two main surfaces, and which face in opposite directions; two longer side surfaces, which connect between the two main surfaces and between the two shorter side surfaces, which face in opposite directions, and the width of which is larger than that of the shorter side surfaces; and a fastening hole that extends through the two longer side surfaces such that a cutting tool fastening bolt is inserted therein, wherein the double-sided cutting insert having a high feed rate comprises a shorter cutting edge provided on a boundary portion between each of the main surfaces and each of the shorter side surfaces, a longer cutting edge provided on a boundary portion between each of the main surfaces and each of the longer side surfaces, and a corner cutting edge that connects between the shorter cutting edge and the longer cutting edge, and the shorter cutting edge has a curved shape that is outwardly convex, when the same is viewed from a direction of the main surfaces.