Rectangular Cutting Insert for Reusable End Mill Edge Switching
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Solution Overview
Problem
Existing end mills require two cutting inserts of different shapes for center and outer peripheral edges, complicating tool management and limiting the reuse of cutting inserts due to asymmetric, complex shapes that cannot be interchanged.
Innovation Solution
A cutting insert with a rectangular first edge line and second edge line, where cutting edges are formed on three sides of the first edge line and two sides of the second edge line, allowing the same insert to be used as both center and outer peripheral edges, with interchangeable front and back surfaces, and a wedge-shaped fourth side surface for stable fixation to the tool body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two different shaped cutting inserts are used for center edge and outer peripheral edge, then the cutting performance is optimized, but the tool management becomes complicated
Solution Approach 1:
The cutting insert is designed with a universal rectangular shape that allows it to function as both center edge and outer peripheral edge cutting inserts. The insert can be mounted in different orientations (front surface or back surface facing the cutting direction) to perform different cutting functions, eliminating the need for separate specialized inserts.
2Reliability
If asymmetric complex shaped cutting inserts are used, then the cutting performance is improved, but the reuse of cutting inserts is limited
Solution Approach 1:
While the overall insert shape is symmetric for reusability, asymmetric features are introduced in the form of inclined side surfaces (third and fourth side surfaces) that create directional cutting edges. This allows the insert to maintain optimal cutting performance when used in different orientations while still being reusable.
Solution Approach 2:
The cutting insert is divided into multiple functional sides (first, second, third, fourth sides) with cutting edges on different sides. By selectively mounting the insert with different sides facing the cutting direction, the same insert can perform multiple cutting functions and be reused up to four times.
3Reliability
If the cutting insert is designed for stable fixation, then the cutting performance is improved, but the complexity of insert shape increases
Solution Approach 1:
The third and fourth side surfaces are designed as inclined surfaces rather than perpendicular to the top and bottom surfaces. This asymmetry creates a wedge-shaped structure that provides stable fixation in the tool holder while maintaining a relatively simple overall rectangular shape of the insert.
Data Source
AI summary
The present disclosure provides a cutting insert that is economical and can be stably fixed to a tool body. A first edge line (10R) of a cutting insert (2) is a rectangle having a first side (11) and a third side (13) as long sides and a second side (12) and a fourth side (14) as short sides. Cutting edges are formed at the first side (11), the second side (12) and the third side (13); on the other hand no cutting edge is formed at the fourth side (14). At a second edge line (20R) having the same shape as the first edge line (10R), a sixth side (22) where a cutting edge is formed is opposite to the fourth side (14), and an eighth side (24) where a cutting edge is not formed is opposite to the second side (12). A peripheral side surface (30) includes a fourth side surface (34) facing the fourth side (14) and the sixth side (22). The fourth side surface (34) extends from a first end surface (10) to a second end surface (20) and is inclined in a direction from the second side (12) to the fourth side (14).