Double-Sided Cutting Insert for Chip Discharge and Reverse Turning
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Solution Overview
Problem
Existing cutting tools face challenges in safely and efficiently discharging metal chips during the cutting process without interrupting continuous operation or causing operator injury, and in maintaining a stable cutting edge for both forward and backward turning operations.
Innovation Solution
A double-sided cutting insert with specific inclined mounting portions and a shim support system that allows for efficient chip discharge and stable mounting during both forward and backward turning, featuring a quadrilateral shape with inclined cutting edges and surfaces for enhanced cutting performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If a conventional cutting insert is used, then the cutting process can be performed, but metal chips cannot be safely and efficiently discharged from the cutting area
Solution Approach 1:
The cutting insert is divided into multiple corner portions (first to fourth corner portions) with distinct inclined mounting portions at each corner. This segmentation allows different regions of the insert to handle chip discharge in different directions, enabling efficient chip evacuation while maintaining continuous cutting operation.
Solution Approach 2:
The inclined mounting portions are configured with asymmetric thickness distributions - some portions decrease toward the thickness direction centerline while others increase. This asymmetric design creates varied chip flow paths from different corners, allowing chips to be discharged safely without interfering with the cutting edge or operator.
2Adaptability or versatility
If the cutting insert structure is simplified, then manufacturing is easier, but the insert cannot support both forward and backward turning operations
Solution Approach 1:
The cutting insert is designed with four corner portions, each having inclined mounting portions configured to accommodate both forward and backward turning operations. The symmetric arrangement of inclined portions at different corners allows the same insert to function universally in multiple cutting directions without requiring different inserts.
Solution Approach 2:
The inclined mounting portions are configured in the thickness direction of the insert, creating a three-dimensional structure that enables bidirectional cutting. By utilizing the thickness dimension with inclined surfaces facing different directions, the insert achieves multi-functionality for both forward and backward turning.
3Reliability
If the cutting insert has uniform thickness, then manufacturing is simpler, but stable mounting during both forward and backward turning cannot be achieved
Solution Approach 1:
Rather than uniform thickness, the insert employs local quality variations with inclined mounting portions having different thickness characteristics at different corners. Specific portions decrease toward the centerline while others increase, creating optimized local structures for stable mounting during various cutting operations while maintaining manufacturability.
Data Source
AI summary
A cutting insert and a cutting tool assembly for cutting a workpiece. The cutting tool assembly includes a cutting insert having an upper surface that has a quadrilateral shape so as to include first to fourth insert corner portions, and a shim configured to support the insert. The insert includes an upper surface and a lower surface on which first to sixth inclined mounting portions are respectively formed. The shim simultaneously supports the first to third inclined mounting portions, or simultaneously supports the fourth to sixth inclined mounting portions.