Curved Minor Cutting Edge for Finish Machining Accuracy
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Solution Overview
Problem
Existing cutting inserts with double-sided designs, such as those described in Patent Document 1, face limitations in surface accuracy during finish machining due to the restricted region of the minor cutting edge that can be used as a flat cutting edge, especially when the axial rake is set to a negative value.
Innovation Solution
The cutting insert features a unique minor cutting edge design with a protruding curved shape, comprising a first portion with an apex, a second portion with a larger radius of curvature, and a third portion with an even larger radius of curvature, allowing a wider region to be used as a flat cutting edge even when the axial rake is negative.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the axial rake is set to a negative value for the cutting insert, then the cutting insert can be used for rough machining and finish machining on both upper and lower surfaces, but the region of the minor cutting edge that can be used as a flat cutting edge is restricted, reducing surface accuracy
Solution Approach 1:
The minor cutting edge is divided into multiple segments with different curvature radii: a first portion with a first curvature radius, a second portion with a second curvature radius larger than the first, and a third portion with a third curvature radius larger than the second. This segmentation allows different portions to serve different functions, expanding the usable region for finish machining while maintaining negative axial rake for versatility.
Solution Approach 2:
Different portions of the minor cutting edge are given different local geometric properties (curvature radii) to optimize their function. The first portion with smaller curvature radius is suitable for certain machining conditions, while the second and third portions with progressively larger curvature radii provide better surface accuracy for finish machining, allowing each local region to have the quality needed for its specific function.
2Device complexity
If the minor cutting edge has a simple curved shape, then the cutting insert structure is simple, but the usable region as a flat cutting edge is limited, affecting finish machining quality
Solution Approach 1:
The minor cutting edge is segmented into three distinct portions with progressively increasing curvature radii. This segmentation creates a more complex geometry that expands the usable region for finish machining, improving surface accuracy while maintaining reasonable structural complexity through a systematic design approach.
Data Source
AI summary
A minor cutting edge in a cutting insert of one aspect has a protruding curved shape protruding upward in a side view and includes: a first portion including an apex portion protruding most upward in the minor cutting edge; a second portion located between the first portion and a connection edge; and a third portion located between the second portion and the connection edge. Each of the second portion and the third portion comes close to a lower surface with distance from the first portion. In the side view, a radius of curvature of the second portion is larger than a radius of curvature of the first portion and a radius of curvature of the third portion.