Cutting Insert Curvature Layout for Vertical Wall Corner Finishing
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Solution Overview
Problem
Indexable ball end mills face challenges in improving process efficiency while maintaining surface accuracy during vertical wall surface processing, particularly in increasing pick feed pitch without exceeding cusp height and failing to perform finishing processes on recessed corner portions.
Innovation Solution
A cutting insert with a convex arc-shaped bottom cutting edge and a larger convex arc-shaped outer peripheral cutting edge, where the curvature radius of the outer peripheral cutting edge is 3.6 to 333 times greater than the bottom cutting edge, allowing for a pitch of pick feed to be increased while maintaining surface accuracy, enabling finishing of vertical wall bottom corners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the pick feed pitch is increased to improve process efficiency, then productivity increases, but the cusp height of the processing surface exceeds the predetermined value, degrading manufacturing precision
Solution Approach 1:
The cutting edge is segmented into two distinct functional zones: a bottom cutting edge with a small curvature radius (0.05 to 5 mm) for finishing the vertical wall bottom corner, and an outer peripheral cutting edge with a large curvature radius (0.5 to 500 mm) for processing the vertical wall surface. This segmentation allows each zone to perform its specific function optimally without interfering with the other, enabling independent optimization of both productivity and surface accuracy.
Solution Approach 2:
Different portions of the cutting edge are given different local qualities through distinct curvature radii. The bottom cutting edge has a small curvature radius to create a sharp cutting point for precise corner finishing, while the outer peripheral cutting edge has a large curvature radius to maintain a stable, low cusp height for high-quality surface processing. This local differentiation resolves the contradiction by allowing the system to achieve both high productivity and high precision through specialized local characteristics.
2Manufacturing precision
If a traditional ball end mill is used to maintain surface accuracy, then manufacturing precision is preserved, but the pick feed pitch must be kept small, reducing productivity
Solution Approach 1:
The cutting edge is divided into two functional segments with different curvature radii, allowing the outer peripheral cutting edge with large curvature radius to handle the majority of the vertical wall surface processing with high pick feed pitch, while the bottom cutting edge with small curvature radius handles the corner finishing. This segmentation eliminates the need to use a small curvature radius throughout the entire cutting edge, thereby resolving the productivity limitation of traditional ball end mills.
Solution Approach 2:
The invention applies local quality by assigning different curvature radii to different portions of the cutting edge based on their specific functional requirements. The outer peripheral region uses a large curvature radius to enable high productivity processing with acceptable cusp height, while the bottom corner region uses a small curvature radius for precise finishing. This local optimization allows the system to achieve high overall productivity without sacrificing surface accuracy in critical areas.
3Adaptability or versatility
If the curvature radius of the bottom cutting edge is made small to finish the vertical wall bottom corner, then the ability to process recessed corners is improved, but the curvature radius becomes too small, reducing reliability of the cutting edge
Solution Approach 1:
The cutting edge is segmented so that the bottom cutting edge has a small curvature radius (0.05 to 5 mm) specifically for corner finishing, while the outer peripheral cutting edge has a large curvature radius (0.5 to 500 mm) for main surface processing. The segmentation isolates the small curvature radius to only where it is needed, protecting the overall cutting edge reliability by keeping the majority of the cutting edge (outer peripheral portion) with a more robust large curvature radius.
Solution Approach 2:
The invention applies local quality by giving the bottom cutting edge a small curvature radius to achieve the specialized function of finishing recessed corners, while the outer peripheral cutting edge maintains a large curvature radius for general-purpose reliable processing. This localized application of small curvature radius minimizes the negative impact on overall cutting edge reliability while achieving the desired adaptability for corner finishing operations.
4Productivity
If the curvature radius of the outer peripheral cutting edge is made large to increase pick feed pitch, then productivity is improved, but the curvature radius becomes excessively large, degrading manufacturing precision
Solution Approach 1:
The cutting edge is segmented into a bottom portion with small curvature radius and an outer peripheral portion with large curvature radius. The outer peripheral cutting edge with large curvature radius (0.5 to 500 mm) is responsible for processing the vertical wall surface and can use a large pick feed pitch, while the bottom cutting edge with small curvature radius (0.05 to 5 mm) handles the corner finishing. This segmentation allows the system to use a large curvature radius where it benefits productivity without allowing it to degrade overall manufacturing precision, as the critical corner finishing is handled by the small curvature radius portion.
Solution Approach 2:
The invention applies local quality by assigning a large curvature radius specifically to the outer peripheral cutting edge where it is needed to enable high pick feed pitch and improved productivity, while the bottom cutting edge maintains a small curvature radius for precision corner finishing. This localized differentiation allows the system to achieve high productivity through the large curvature radius portion without sacrificing manufacturing precision in the critical corner regions processed by the small curvature radius portion.
Data Source
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AI summary
A cutting insert includes a rake face, a flank surface, and a cutting edge, the cutting edge includes a bottom cutting edge that is positioned at a front end in a central axis direction and forms a convex arc shape and an outer peripheral cutting edge that is aligned with a radial-direction outer end of the bottom cutting edge and forms a convex arc shape of which a curvature radius is larger than that of the bottom cutting edge, an angle formed between a tangent line to a boundary point between the bottom cutting edge and the outer peripheral cutting edge and the central axis is less than 45°, a curvature radius R1 of the bottom cutting edge is 0.3 to 10 mm, and a ratio (R2/R1) of a curvature radius R2 of the outer peripheral cutting edge to the curvature radius R1 of the bottom cutting edge is 3.6 to 333.