Curved Cutting Insert Design Reduces Load and Enhances Squareness
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Solution Overview
Problem
Conventional double-sided cutting inserts face issues with increased cutting load, reduced squareness, limited helix angle, and difficulty in enhancing cutting performance and surface roughness due to their flat and straight edge configurations.
Innovation Solution
A cutting insert design featuring angled end surfaces, main side surfaces, and auxiliary side surfaces with obtuse angles and curved cutting edges, which reduces cutting load, enhances squareness, and increases helix angle for improved cutting performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the major side surface is made flat, then the manufacturing is simplified, but the cutting load increases and squareness is reduced
Solution Approach 1:
The patent applies curvature to the major side surface by forming a relieved surface that curves away from the cutting edge. This relieved surface creates a rounded profile instead of a flat surface, which reduces the cutting load by allowing chips to flow more smoothly while maintaining or improving squareness through the geometric configuration of the relieved surface.
2Ease of manufacture
If the major cutting edge has a straight line shape, then the manufacturing is simplified, but the helix angle is limited and cutting performance cannot be enhanced
Solution Approach 1:
The patent forms the major cutting edge with a curved profile instead of a straight line. The cutting edge follows an arc that allows for a greater helix angle, improving chip evacuation and cutting performance. The curved cutting edge is created through the relieved surface geometry that rounds the edge while maintaining sharpness.
3Ease of manufacture
If the double-sided cutting insert has a rectangular shape, then the manufacturing is simplified, but the cutting load increases during full feeding and squareness is reduced
Solution Approach 1:
The patent modifies the rectangular shape by introducing asymmetry through the relieved surface. The relieved surface creates an uneven profile where one side curves away more than the other, breaking the symmetry of the rectangular form. This asymmetric configuration reduces cutting load during full feeding by optimizing chip flow paths while maintaining squareness through careful geometric design.
4Ease of manufacture
If the minor cutting edge has a straight line shape, then the manufacturing is simplified, but the surface roughness of the workpiece cannot be enhanced
Solution Approach 1:
The patent applies curvature to the minor cutting edge through the relieved surface geometry. The minor cutting edge is formed with a rounded profile that follows an arc, which improves surface roughness by creating a more gradual transition during cutting. This curved edge reduces vibration and produces a smoother finish on the workpiece surface.
Data Source
AI summary
The purpose of the present invention is to provide a cutting insert capable of reducing cutting load and enhancing squareness. A cutting insert, according to one embodiment of the present invention, comprises: first and second end surfaces which face opposite directions to each other and have four corners wherein two ascending corners are placed in one diagonal position, and two descending corners lower than the height of the ascending corners are placed in the remaining diagonal position; first and second main side surfaces which are placed between the first and second end surfaces, face in opposite directions to each other, and have a throughhole connecting the first and second main side surfaces to each other; and first and second auxiliary side surfaces placed between the first and second end surfaces and between the first and second main side surfaces, wherein, when seen from the first or second end surface, each of the first and second main side surfaces comprises: a central main clearance surface placed on a central portion thereof; a first peripheral main clearance surface which is placed between the central main clearance surface and the ascending corners, and which forms an obtuse angle with respect to the central main clearance surface such that the central main clearance surface may protrude; and a second peripheral main clearance surface which is placed between the central main clearance surface and the descending corners, and forms an obtuse angle with respect to the central main clearance surface such that the central main clearance surface may protrude.