Cutting Insert Asymmetric Flank Surfaces Clearance Angle
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Solution Overview
Problem
Existing cutting inserts face challenges in maintaining a sufficient clearance angle between the flank surface and the workpiece while ensuring a large axial rake angle, leading to frictional heat generation and early wear due to increased cutting resistance.
Innovation Solution
A cutting insert design with an upper and lower flank surface configuration, where the upper flank surface is closer to the central axis and the lower flank surface is separated, allowing for a larger clearance angle without tilting the insert forward, reducing cutting resistance and enabling a relatively large axial rake angle without increasing the insert's thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the forward inclination angle of the cutting insert is decreased to ensure a large axial rake angle, then the axial rake angle is improved, but the clearance angle between the flank surface and the workpiece becomes insufficient
Solution Approach 1:
The invention transitions from a single-plane inclination approach to a three-dimensional asymmetric flank surface configuration. By making the upper flank surface closer to the central axis and the lower flank surface separated from it, the solution operates in multiple spatial dimensions to simultaneously achieve both large axial rake angle and sufficient clearance angle without requiring forward tilting of the insert.
Solution Approach 2:
The invention applies asymmetry by creating different configurations for the upper and lower flank surfaces relative to the central axis. The upper flank surface is positioned closer to the central axis while the lower flank surface is separated from it, forming an asymmetric structure that enables both cutting edges to have optimal geometry without requiring the insert to be tilted forward.
2Force
If the forward inclination angle is decreased to ensure large axial rake angle, then the axial rake angle is improved, but frictional heat generation increases due to contact between the flank surface and the workpiece
Solution Approach 1:
The asymmetric configuration of the upper and lower flank surfaces relative to the central axis creates sufficient clearance between the flank surfaces and the workpiece during cutting operations. This eliminates unwanted contact and the resulting frictional heat generation while preserving the large axial rake angle geometry.
3Force
If the forward inclination angle is decreased to ensure large axial rake angle, then the axial rake angle is improved, but the insert thickness must be increased to ensure sufficient strength
Solution Approach 1:
Instead of compensating for strength requirements by increasing insert thickness in the traditional forward-inclination approach, the invention utilizes the third dimension (asymmetric positioning of upper and lower flank surfaces relative to the central axis) to achieve both large axial rake angle and sufficient structural strength with minimal thickness increase.
4Adaptability or versatility
If the second side surface includes both upper and lower flank surfaces, then the clearance angle effect can be produced in both cutting directions, but the device complexity increases
Solution Approach 1:
The asymmetric flank surface configuration on the second side surface serves multiple functions: it provides sufficient clearance angle for both upper and lower cutting edges, enables the insert to be used in both forward and reverse cutting directions, and maintains structural strength. This multi-functional design achieves versatility without excessive complexity.
Data Source
AI summary
A cutting insert includes an upper surface; a lower surface; a side surface which is connected to each of the upper surface and the lower surface and includes a first side surface, a second side surface and a third side surface being adjacent to each other in order; an upper cutting edge including an upper major cutting edge located at an intersection of the upper surface and the first side surface, and an upper flat cutting edge located closer to the upper major cutting edge in an intersection of the upper surface and the second side surface; and a lower cutting edge including a lower major cutting edge located at an intersection of the lower surface and the third side surface, and a lower flat cutting edge located closer to the lower major cutting edge in an intersection of the lower surface and the second side surface. The second side surface comprises an upper flank surface connected to the upper flat cutting edge, and a lower flank surface connected to the lower flat cutting edge. As going from the upper surface to the lower surface, the upper flank surface is closer to a central axis extending between the upper surface and the lower surface and the lower flank surface is separated from the central axis in a side sectional view. A cutting tool including the cutting insert, and a method of manufacturing a machined product by using the cutting tool are also provided.