Curved Cutting Insert Edge for Lower Milling Forces
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Solution Overview
Problem
Conventional cutting inserts for high feed milling experience high cutting forces and reduced tool life due to chip rolling and uneven cutting edge engagement, which leads to inefficient machining and increased wear.
Innovation Solution
A cutting insert design featuring a convex portion with adjoining concave portions, increasing the contact length of the cutting edge, allowing for a peeling cut and reducing chip rolling, thereby lowering cutting forces and enhancing tool life through a more elongated chip formation and efficient heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If a conventional cutting edge design is used, then the cutting insert can be manufactured with simple geometry, but high cutting forces and chip rolling occur leading to reduced tool life
Solution Approach 1:
The cutting edge is designed with a convex portion that is curved upwardly and outwardly, bounded by concavely curved portions. This curvature configuration increases the contact length of the cutting edge with the workpiece, distributing cutting forces over a longer section and reducing peak forces. The curved geometry also promotes peeling cut action and prevents chip rolling, thereby extending tool life while reducing cutting forces.
2Force
If the cutting edge contact length is increased through convex and concave portions, then cutting forces are reduced and tool life is extended, but the manufacturing complexity of the cutting insert increases
Solution Approach 1:
The cutting edge geometry is defined by specific curvature parameters - a convex portion with radius R1 and concave portions with radius R2, where R2 is 3 to 6 times R1. By standardizing these geometric parameters and their relationships, the complex curved geometry can be manufactured with precision using conventional forming processes, balancing the need for reduced cutting forces against manufacturing complexity.
Data Source
AI summary
A cutting insert has a substantially triangular or square basic shape with a top surface and a base surface that are connected together by lateral flanks. A cutting edge is formed at the transition between at least one flank and the top surface. The cutting edge extends between cutting corners, and the cutting edge has a portion that is convex in side view of a flank. The convex portion of the cutting edge is bounded on both sides by concavely curved portions.