Double-Sided Cutting Insert With Convex Corners for Secure Mounting
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Solution Overview
Problem
Double-sided indexable cutting inserts face issues with secure mounting due to deformations causing deviations in supporting surfaces, leading to vibrations and reduced tool lifespan during severe cutting conditions, and existing mounting methods like screws or levers provide inadequate clamping force, resulting in dislodgment.
Innovation Solution
A polygonal double-sided cutting insert with convex portions at corners and a reinforcing part with flat portions for secure contact, along with a top-bottom symmetrical through-hole and an L-shaped lever that exerts lateral and downward pressures to stabilize the insert on the tool holder.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the supporting surfaces are ground flat on a single-sided cutting insert, then secure mounting on the tool holder is achieved, but the double-sided symmetrical structure prevents grinding and causes deviations in supporting surface level
Solution Approach 1:
The invention applies local quality by providing convex portions at specific corner locations of the cutting insert rather than requiring the entire supporting surface to be perfectly flat. These localized convex portions make contact with corresponding concave portions on the reinforcing part, ensuring stable mounting while preserving the double-sided symmetrical structure of the cutting insert.
Solution Approach 2:
Instead of grinding the supporting surface flat to achieve secure mounting, the invention inverts the approach by creating convex portions that protrude from the supporting surface. This allows the cutting insert to be securely mounted through positive engagement of these convex portions with concave portions on the reinforcing part, eliminating the need for flat grinding while maintaining double-sided symmetry.
2Ease of operation
If contact surfaces are formed by machine pressing, then mounting is simplified, but deformations cause deviations in supporting surface height leading to vibrations
Solution Approach 1:
The invention focuses contact and clamping forces on specific localized convex portions at the corners rather than distributing them across the entire supporting surface. This localized approach ensures that even if deformations occur during pressing, the critical contact points maintain proper engagement with the reinforcing part, preventing vibrations while keeping the mounting process simple.
Solution Approach 2:
The convex portions are designed with specific geometries that anticipate and compensate for potential deformations during the pressing process. By pre-shaping these convex portions to account for expected deformations, the invention ensures that the supporting surfaces remain at correct relative heights after mounting, preventing vibrations without requiring complex mounting procedures.
3Reliability
If a screw is used to mount the cutting insert, then the insert can be secured, but the clamping force is limited and the screw wears out reducing effectiveness
Solution Approach 1:
The invention segments the clamping function from the single screw into multiple contact points through convex portions at the corners. Each convex portion engages with a corresponding concave portion on the reinforcing part, distributing the clamping force across multiple locations. This segmentation provides superior securing reliability compared to a single screw while maintaining ease of operation for insert replacement.
Solution Approach 2:
The invention adds a vertical dimension to the clamping mechanism by creating convex portions that protrude upward from the supporting surface. These convex portions engage with recesses in the reinforcing part, providing clamping force in the vertical direction that complements the horizontal clamping force from the screw, thereby significantly enhancing overall clamping effectiveness without increasing screw wear.
4Force
If a lever is used to mount the cutting insert, then good clamping force against the tool holder wall is achieved, but poor clamping force against the bottom causes insert lift during cutting
Solution Approach 1:
The invention segments the clamping function into lateral and vertical components through the convex portions. The lever provides lateral clamping force against the tool holder wall, while the convex portions simultaneously provide vertical clamping force against the reinforcing part bottom. This segmentation ensures both lateral and downward clamping forces are adequate, preventing insert lift during severe cutting conditions.
Solution Approach 2:
The convex portions add a vertical dimension to the clamping mechanism, working in conjunction with the lever's horizontal clamping action. This creates a three-dimensional clamping system where the lever provides lateral force and the convex portions provide vertical force, ensuring the cutting insert is securely held against both the tool holder wall and the reinforcing part bottom, eliminating the lift problem.
Data Source
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AI summary
The present invention relates to an assembly of a double-sided indexable cutting insert and a reinforcing part, which is used to process metallic materials and the like. The polygonal, double-sided indexable cutting insert of the present invention comprises a plurality of convex portions at each corner portion. The level of the convex portions is lower than that of the corner cutting edges. Further, the reinforcing part of the present invention comprises flat portions that come into contact with the convex portions of the cutting insert at each corner portion. When the cutting insert and the reinforcing part are assembled together, the flat portions of the reinforcing part contact at least three convex portions of the cutting insert.