Cutting Insert With Angled Abutment Surfaces For Vibration Control
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Solution Overview
Problem
Cutting tools used for face-shaping or face-grooving operations face challenges in providing both sufficient reach and robust mechanical support, as they often need to be shaped long and thin, leading to vibration issues that affect surface quality.
Innovation Solution
A cutting insert design featuring a tool body with a pocket and clamping mechanism using angled abutment surfaces that securely mount the cutting insert with three-point contact, providing stability and accurate positioning through a clamping bolt, allowing for robust support while maintaining a small diameter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the cutting tool is made long to provide sufficient reach for internal surface operations, then the reach is improved, but the robustness deteriorates due to excessive vibration
Solution Approach 1:
The cutting tool is divided into separate components: a tool body and a cutting insert mounted in a pocket. This segmentation allows the tool body to be optimized for reach while the insert provides the cutting function, reducing the need for a long, thin structure that would be prone to vibration.
Solution Approach 2:
The cutting insert is designed with a three-dimensional mounting structure featuring angled abutment surfaces and multiple contact points. This dimensional approach distributes clamping forces across multiple surfaces, enhancing stability without increasing the tool's length or compromising reach.
2Area of moving object
If the cutting tool is made with a small cross section to maintain compactness, then the robustness is improved, but the reach deteriorates due to inability to access deep surfaces
Solution Approach 1:
By separating the tool body from the cutting insert and using a pocket mounting system, the design achieves a compact cross-section while maintaining extended reach capability. The insert can be securely mounted in a deep pocket, allowing the tool body to remain compact.
Solution Approach 2:
The cutting insert is nested within the tool body's pocket structure, allowing the cutting element to extend beyond the tool body's outer dimensions. This nesting approach enables deep reach into workpieces while keeping the tool body's cross-section compact.
3Adaptability or versatility
If the cutting tool surfaces are curved to avoid interference with the workpiece, then the adaptability is improved, but the mechanical support deteriorates making it difficult to provide robust support
Solution Approach 1:
The separation of the tool body and cutting insert allows the tool body to maintain curved, adaptable surfaces for accessing complex workpiece geometries, while the rigid insert mounting structure provides the necessary mechanical support and stability.
Solution Approach 2:
Different parts of the tool have different surface characteristics: the tool body has curved surfaces for adaptability, while the pocket and abutment surfaces have precise geometric shapes for providing localized mechanical support and stable insert mounting.
4Stability of the object's composition
If a clamping mechanism with multiple contact points is used to secure the cutting insert, then the stability is improved, but the device complexity increases
Solution Approach 1:
Multiple clamping functions are merged into a single clamping bolt mechanism that acts against angled abutment surfaces. This single mechanism simultaneously provides clamping force, positioning, and stability, avoiding the need for multiple separate clamping elements.
Solution Approach 2:
The angled abutment surfaces are designed with specific geometric curvatures that concentrate clamping forces at precise contact points. This geometric design achieves stable three-point contact and secure positioning without requiring complex adjustable mechanisms.
Data Source
Figure 1A
Figure 1B~1C
Figure 2A
AI summary
The present invention relates to a cutting insert (50) comprising a cutting portion (54), the cutting portion (54) constituting a forward portion of the cutting insert (50) and comprising at least one cutting edge (55), and a mounting portion (52), the mounting portion constituting a rearward portion of the cutting insert (50) and comprising inner (56) and outer surfaces (57) and a peripheral surface (58) extending therebetween, a through bore (62) passing through the inner and outer surfaces (56,57), first and second insert abutment surfaces (157,158) located on the peripheral surface (58), the first and second insert abutment surfaces (157,158) being situated at a greater distance from the cutting portion (54) than the through bore (62) and being oriented at an acute angle to each other and converging in a direction away from the at least one cutting edge (55), and a third insert abutment surface (160) located adjacent, and oriented transversely to, the inner surface (56) but spaced apart from the peripheral surface (58) and situated closer to the cutting portion (54) than the through bore (62).