Cutting Insert Asymmetric Corner Geometry Wear Reduction

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Solution Overview

Problem

Prior cutting inserts with truncated corners face issues of increased wear due to smaller radii and potential engagement with the workpiece, limiting indexability and chip uniformity.

Innovation Solution

A cutting insert with 180° rotational symmetry and 90° symmetry around a second axis, featuring support surfaces and specially shaped minor edges to prevent engagement with the workpiece, while maintaining larger angles for uniform chip formation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If the corner of the cutting insert is truncated to increase indexability, then the degree of indexability is improved, but the radius connecting each lateral face and the face of the truncated corner becomes smaller causing increased wear

Engineering Contradiction:

ImproveindexabilityVSAvoidwear resistance

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The cutting insert employs asymmetric corner geometry where the truncated corner features an obtuse angle (greater than 90 degrees) between lateral faces, rather than symmetric 90-degree corners. This asymmetric design allows larger effective radii at the cutting edge while maintaining the truncated corner configuration for indexability, thereby reducing wear on the cutting edge.

Inventive Principle:

Principle #4Asymmetry

2Strength

If the corner angle is increased to allow smaller radius, then the radius may be smaller without concern of corner breaking, but the chip uniformity deteriorates

Engineering Contradiction:

Improvecorner strengthVSAvoidchip uniformity

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The cutting insert applies different geometric characteristics to different regions: the truncated corner region has obtuse angles for strength, while the cutting edge region maintains appropriate radius curvature for chip uniformity. This local differentiation of geometric properties allows both corner strength and chip quality to be optimized simultaneously.

Inventive Principle:

Principle #3Local quality

3Ease of operation

If the standard entering angle of 45° is used, then the cutting edge performs standard cutting, but the face of the truncated corner undesirably engages the workpiece

Engineering Contradiction:

Improvecutting performanceVSAvoidworkpiece engagement

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The solution addresses the workpiece engagement problem by modifying the geometry in a different dimensional aspect - specifically by changing the corner angle to obtuse (greater than 90 degrees) and adjusting the relative positioning of the truncated corner face. This dimensional change in angular geometry prevents the truncated corner from engaging the workpiece while maintaining the 45-degree entering angle for proper cutting action.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Data Source

PatentEP1893377B1Cutting insert

Publication Date: 2012.07.18 ISCAR LTD

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AI summary

A cutting insert (10) comprising two opposing end surfaces (2) , a peripheral side surface (14) extending therebetween and a peripheral edge (30) formed at an intersection of each end surface (12) with the peripheral side surface (14) , at least one peripheral edge (30) comprises two minor edges (36) and a cutting edge (32) extending therebetween, a first section (38) of each minor edge (36) extending from the cutting edge (36) generally towards the opposing end surface (12) .