Indexable Cutting Insert Structure for Accurate Clamping and More Blades
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional cutting inserts with positive shapes face accuracy issues during attachment to cutting tools and struggle to increase the number of blades due to their design, leading to poor machining precision and efficiency.
Innovation Solution
A cutting insert with a unique shape featuring a flat reference surface orthogonal to the cutting edges, inclined end surfaces, and curved cutting edges on both the upper and lower surfaces, allowing for stable attachment and increased rigidity, enabling more blades to be mounted without widening the insert.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a positive shape is used to ensure sharpness, then cutting edge sharpness is improved, but attachment accuracy deteriorates
Solution Approach 1:
The cutting insert is divided into distinct functional surfaces: a positive-shaped cutting edge portion for sharpness and a separate flat reference surface for accurate attachment. This segmentation allows each surface to optimize its specific function without compromising the other.
Solution Approach 2:
Different surfaces of the cutting insert have different geometric properties tailored to their specific functions: the cutting edge has a positive shape for sharpness while the reference surface has a flat geometry for attachment precision. Each local area has the quality needed for its purpose.
2Productivity
If the number of corners in one cutting insert is increased, then the number of blades is increased, but the insert width becomes large
Solution Approach 1:
The cutting edges are arranged not only along the width but also along the length of the insert, utilizing both dimensions efficiently. The curved cutting edges extend in the lengthwise direction, allowing multiple cutting points to be packed into a compact insert footprint.
Solution Approach 2:
Multiple cutting edges are nested along the curved perimeter of the insert, with cutting edges positioned on both the upper and lower surfaces. This nesting arrangement maximizes the number of usable blades within the constrained insert dimensions.
3Strength
If end surfaces are made parallel to each other, then rigidity of the insert clamp is improved, but the complexity of the shape increases
Solution Approach 1:
The end surfaces are inclined at specific angles (e.g., 15-45 degrees) relative to the upper and lower surfaces, creating an asymmetric dovetail configuration. This asymmetric geometry provides mechanical interlocking that enhances rigidity while maintaining manufacturability through standard machining operations.
Data Source
AI summary
Provided is a structure for improving accuracy in attaching a cutting tool to a body and making it possible to increase the number of blades while the cutting tool is mounted on the body. A cutting insert 1 includes: an upper surface 10 that has a shape with a lengthwise direction LD and a widthwise direction SD; a lower surface that is located opposite to the upper surface 10; a peripheral side surface 30 that is formed so as to connect the upper surface 10 and the lower surface; cutting edges 51 and 52 that are respectively formed on an intersecting ridge line of the upper surface 10 and the peripheral side surface 30, and on an intersecting ridge line of the lower surface and the peripheral side surface 30, and each have a curved ridge line that extends in a lengthwise direction thereof; and a through hole 60 that penetrates from the upper surface 10 to the lower surface. End surfaces 31 and 32 located in the lengthwise direction LD of the upper surface 10 and the lower surface, of the peripheral side surface 30, are respectively inclined with respect to the upper surface 10 and the lower surface, and are parallel to each other. A reference surface 33 that is located opposite to the cutting edges 51 and 52, of the peripheral side surface 30, is a flat surface that is orthogonal to the upper surface 10 and the lower surface.