Cutting Insert Asymmetric Edges Reduce Cutting Force
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Solution Overview
Problem
Existing cutting inserts face limitations in increasing machining efficiency due to increased chip thickness and cutting force as feed rate increases, and surface roughness issues arise from the approach angle, restricting further efficiency gains.
Innovation Solution
A cutting insert design featuring a major cutting edge with an approach angle of 35° or smaller and a minor cutting edge with an angle of 145° or larger, allowing the minor cutting edge to function as a flat cutting edge, reducing chip thickness and surface roughness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the feed rate is increased to improve machining efficiency, then productivity increases, but chip thickness and cutting force increase making further feed rate increases difficult
Solution Approach 1:
The cutting insert is divided into multiple cutting edges (first through fourth cutting edges) arranged at different positions and orientations. This segmentation allows the workload to be distributed across multiple edges, reducing the cutting force on each individual edge while maintaining high productivity through continuous cutting capability.
Solution Approach 2:
The cutting insert employs an asymmetric configuration where cutting edges are positioned at different locations (e.g., first cutting edge at one corner, second at opposite corner, third and fourth at adjacent corners) with different orientations. This asymmetric arrangement optimizes chip thickness distribution and reduces cutting forces compared to symmetric configurations.
2Productivity
If the approach angle is increased to improve machining efficiency, then productivity increases, but surface roughness increases due to adverse effect of approach angle
Solution Approach 1:
The cutting insert uses multiple cutting edges positioned at different corners, with at least one cutting edge configured to function as a flat cutting edge. This segmentation allows the flat cutting edge to specifically address surface finish requirements while other edges handle material removal, resolving the conflict between productivity and surface quality.
Solution Approach 2:
The cutting insert is designed to perform multiple functions with different cutting edges: some edges are optimized for aggressive material removal while others serve as flat cutting edges for surface finishing. This multi-functionality allows a single insert to achieve both high productivity and good surface roughness without requiring separate tools.
3Manufacturing precision
If the minor cutting edge angle is set to 45° to function as flat cutting edge, then surface roughness improves, but the length of minor cutting edge is limited restricting feed rate increase
Solution Approach 1:
The cutting insert employs asymmetric angle configurations for different cutting edges. At least one cutting edge is designed with an angle of 145° or more to function as a flat cutting edge for good surface finish, while other cutting edges use different angles optimized for material removal. This asymmetric design allows the flat cutting edge to achieve surface finishing without limiting the feed rate for other edges.
Solution Approach 2:
Different cutting edges are assigned different local qualities (angles) based on their specific functions. The flat cutting edge has a larger angle (145° or more) optimized for surface finish, while other edges have angles optimized for chip thickness and material removal rate. This local quality differentiation resolves the conflict between surface roughness and feed rate.
Data Source
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AI summary
An object is to provide a cutting insert for a milling cutter with which efficiency in machining can be increased. The cutting insert includes two polygonal main surfaces facing each other and side surfaces each connected to a corresponding side of each of the main surfaces. The side surfaces include a major side surface through which an attachment hole extends, a first minor side surface perpendicular to the major side surface, and a second minor side surface disposed between the first minor side surface and the major side surface. A ridge between each of the main surfaces and the major side surface forms a major cutting edge, and a ridge between each of the main surfaces and the second minor side surface forms a minor cutting edge. An angle between the major cutting edge and the minor cutting edge is 145° or larger.