Cutting Insert Geometry for Secure Holding After Edge Breakage
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Solution Overview
Problem
Existing cutting tools fail to adequately hold the cutting insert when one of the cutting parts breaks, rendering the entire insert unusable before all parts are utilized.
Innovation Solution
The cutting insert design includes recessed outer circumferential surfaces with V-shaped virtual arcs that allow the tool body to engage with non-cutting parts, ensuring secure attachment even if one cutting part is broken, utilizing a tool body with multiple contact points and angled screw fixation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the tool body holds the cutting insert only through contact with cutting parts, then the structure is simple, but the cutting insert becomes unusable when one cutting part breaks
Solution Approach 1:
The outer circumferential surface is segmented into four cutting parts and multiple non-cutting outer circumferential surface parts. The non-cutting parts serve as dedicated holding contact portions, separating the cutting function from the holding function. This allows the tool body to contact both cutting parts (for cutting) and non-cutting parts (for secure holding), ensuring the cutting insert remains usable even if cutting parts break.
2Productivity
If the cutting insert has four cutting parts, then the productivity increases, but the risk of complete failure increases when one part breaks
Solution Approach 1:
Different parts of the outer circumferential surface have different functions: four cutting parts for material removal and multiple non-cutting outer circumferential surface parts for holding. This local differentiation ensures that cutting parts can be used for productivity while non-cutting parts provide backup holding capability, allowing the insert to remain usable even after cutting part failure.
3Reliability
If the outer circumferential surface has recessed portions, then the tool body contact is improved, but the manufacturing complexity increases
Solution Approach 1:
The non-cutting outer circumferential surface parts are formed with curved surfaces that correspond to the spherical contact geometry of the tool body. This curvature design naturally guides the tool body into proper contact positions and maintains stable contact during operation, improving holding reliability while the curvature can be efficiently generated through standard molding or machining processes.
Data Source
AI summary
To provide a cutting insert such that a tool body can sufficiently hold the cutting insert even if one of cutting parts is broken. The cutting insert includes two side surfaces opposed to each other, a fixing hole passing through the centers of the two side surfaces, and an outer circumferential surface that is disposed between the outer circumferential edges of the two side surfaces and are connected to the outer circumferential edges of the two side surfaces. The outer circumferential surface includes four cutting parts, a first outer circumferential surface part that is disposed between the first cutting part and the second cutting part, and a second outer circumferential surface part that is opposed to the first outer circumferential surface part and is disposed between the third cutting part and the fourth cutting part. In a side view of the side surfaces from the axial direction of the fixing hole, the first outer circumferential surface part and the second outer circumferential surface part each have the center recessed toward the fixing hole, and a virtual arc having the same diameter as the diameter of the circumcircle of the cutting insert is in contact with two points on each of the outer circumferential surface parts.