Cutting Insert Asymmetric Side Angles for Ramp Milling
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Solution Overview
Problem
Existing cutting inserts face challenges in preventing interference between machined surfaces and non-cutting edges, and struggle with strength at the corner portion where high cutting resistance occurs, particularly during ramp milling and face milling processes.
Innovation Solution
A cutting insert design featuring a top and bottom surface with side surfaces forming obtuse and acute angles, including a main cutting edge, an inclined cutting edge for ramp milling, and a minor cutting edge, with the second side surface forming a greater obtuse angle with the bottom surface than the first side surface, enhancing corner strength and preventing interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the minor cutting edge is positioned lower than the main cutting edge to prevent interference with machined surfaces, then interference is reduced, but the corner portion becomes thin and lacks sufficient strength to handle high cutting resistance
Solution Approach 1:
The patent applies asymmetry by making the second side surface form a greater obtuse angle with the bottom surface than the first side surface. This asymmetric angular configuration allows the corner portion to maintain sufficient thickness and strength while still positioning the minor cutting edge to prevent interference with machined surfaces during milling operations.
Solution Approach 2:
The patent introduces a dimensional solution by varying the angular configuration of side surfaces relative to the bottom surface. By adjusting the obtuse angles of different side surfaces, the design creates a three-dimensional geometry that simultaneously achieves adequate corner strength and proper cutting edge positioning without compromising either requirement.
2Strength
If the side surface below the main cutting edge is designed with a small clearance angle to maintain strength, then the main cutting edge strength is preserved, but interference occurs between the side surface and the base wall during ramp milling
Solution Approach 1:
The patent resolves this contradiction by making the obtuse angle of the second side surface greater than that of the first side surface. This asymmetric design allows the side surface to have sufficient clearance angle for ramp milling operations while maintaining the strength of the main cutting edge through the optimized angular configuration.
3Ease of manufacture
If the cutting insert is designed with standard side surface angles, then manufacturing is simplified, but it is difficult to prevent non-cutting edges from contacting the machined surface
Solution Approach 1:
The patent applies asymmetry by specifying that the second side surface forms a greater obtuse angle with the bottom surface than the first side surface. This asymmetric angular design effectively positions the minor cutting edge to prevent contact with machined surfaces while remaining manufacturable through standard angular specifications.
Data Source
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AI summary
The present invention provides a cutting insert comprising a top surface, a bottom surface, a plurality of side surfaces that connect the top and bottom surfaces and form an obtuse angle with the bottom surface as well as an acute angle with the top surface. The side surfaces comprise a first side surface and a second side surface, which form an obtuse angle with each other when seen from the above. A main cutting edge is formed at an intersection between the first side surface and the top surface. An inclined cutting edge, which is only for ramp milling, and a minor cutting edge are formed at an intersection between the second side surface and the top surface. An obtuse angle, which the second side surface forms with the bottom surface, is greater than that which the first side surface forms with the bottom surface.