Cutting Insert With Distinct Roughing And Finishing Edges
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional cutting inserts require multiple tools or multiple processing steps to perform roughing and finishing processing of grooves, as they typically have identical cutting edges for the same type of processing, leading to inefficiencies.
Innovation Solution
A cutting insert with two distinct cutting edges, where the first cutting edge extends along corner portions of the first surfaces and the second cutting edge extends between the second surfaces, allowing for independent operation and efficient performance of both roughing and finishing processing without the need for additional tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a conventional cutting insert with identical cutting edges is used, then the structure is simple and easy to manufacture, but multiple tools or multiple processing steps are required to perform both roughing and finishing processing
Solution Approach 1:
The cutting insert is designed with two distinct cutting edges: a first cutting edge for roughing processing and a second cutting edge for finishing processing. This multi-functional design allows a single cutting insert to perform both roughing and finishing operations, eliminating the need for multiple separate tools or processing steps, thereby improving productivity while maintaining reasonable structural complexity
Solution Approach 2:
The cutting insert structure is segmented into distinct functional zones with different cutting edges positioned at specific locations. The first cutting edge is configured for roughing while the second cutting edge is configured for finishing, allowing each edge to be optimized for its specific function. This segmentation enables the single insert to handle multiple processing stages
2Reliability
If multiple rotary cutting tools are used for roughing and finishing processing, then each tool can be optimized for its specific function, but the device complexity and cost increase
Solution Approach 1:
Instead of using separate optimized tools for roughing and finishing, the invention integrates both functions into a single cutting insert with two differently configured cutting edges. The first cutting edge is optimized for roughing while the second is optimized for finishing, allowing one tool to replace multiple tools while maintaining processing quality through proper edge configuration
Solution Approach 2:
The invention merges the functions of multiple cutting tools into a single cutting insert. By combining the roughing capability (first cutting edge) and finishing capability (second cutting edge) in one insert, the system reduces the number of tools required while maintaining the reliability and quality of both processing stages
3Manufacturing precision
If multiple processing processes are used for roughing and finishing, then each process can be optimized independently, but the processing time and complexity increase
Solution Approach 1:
The cutting insert is segmented into two functionally distinct cutting edges, allowing both roughing and finishing operations to be performed with a single tool. This segmentation enables independent optimization of each cutting edge for its specific function while eliminating the need for separate processing processes, thereby reducing processing time without compromising groove processing quality
Solution Approach 2:
The invention enables continuous useful action by allowing both roughing and finishing processing to be performed in sequence using the same cutting insert without interrupting the machining operation. The first cutting edge performs roughing followed by the second cutting edge performing finishing, maintaining continuous productive action and eliminating idle time between tool changes or process transitions
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
A cutting insert (1) according to an aspect of the present invention is provided with two opposite first surfaces (2a, 2b), and a peripheral surface (3) extending between the two first surfaces. A first cutting edge (7) is formed on an edge of one first surface of the two first surfaces. A rake surface (9) related to the first cutting edge (7) extends on the one first surface. A second cutting edge (8) is formed on an edge of one second surface of two opposite second surfaces (4a, 4b) in the peripheral surface (3). A rake surface (10) related to the second cutting edge (8) extends on the one second surface. The second cutting edge (8) has a different function from the first cutting edge (7).