Cutting Insert Flank Layout for Accurate Bottoming and Ramping
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Solution Overview
Problem
Existing cutting inserts face challenges in achieving high bottom-surface accuracy and efficient ramping while maintaining manufacturability, as they often require complex grinding processes and multiple passes due to uneven angles and undercuts, making them difficult to manufacture using dies.
Innovation Solution
A cutting insert design with a peripheral side surface perpendicular to the end surfaces, allowing the wiper edge and inner edge flanks to be on different planes, enabling efficient machining in both radial and oblique directions without undercuts, and facilitating grinding with fewer passes, thus improving manufacturability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the flank of the wiper edge and the flank of the inner edge are located on the same plane, then ramping efficiency is improved, but bottom-surface accuracy deteriorates due to interference with the workpiece
Solution Approach 1:
The invention relocates the flank of the wiper edge from the same plane as the inner edge flank to a different plane, creating a stepped configuration. This dimensional change allows the wiper edge to clear the workpiece during ramping operations while the inner edge maintains bottom-surface accuracy, resolving the interference problem that previously forced a trade-off between ramping efficiency and machining precision.
2Adaptability or versatility
If the side surface is divided into quarters with different angles for wiper edges and inner edges, then both radial and oblique machining capabilities are achieved, but manufacturing complexity increases due to requiring multiple grinding passes
Solution Approach 1:
The side surface is segmented into distinct planes, with each plane dedicated to specific cutting edges. The first side surface contains the flank of the first major cutting edge, the second side surface contains the flank of the first wiper edge on a different plane, and the third side surface contains the flank of the first inner edge. This segmentation allows each surface to be ground independently with appropriate angles, achieving versatile machining capability while simplifying the overall grinding process through systematic division of tasks.
3Ease of manufacture
If the peripheral side surface is made perpendicular to the end surfaces, then manufacturability is improved by eliminating undercuts, but the flank angles of different cutting edges must be accommodated on different planes
Solution Approach 1:
The invention employs asymmetric arrangement of flanks relative to the perpendicular peripheral side surfaces. Each cutting edge's flank is positioned on a specific side surface at an optimized angle for its function, rather than forcing symmetric or uniform angle configurations. This asymmetric design allows the peripheral side surfaces to remain perpendicular (simplifying manufacturing) while accommodating the diverse angular requirements of different cutting edges through strategic placement on different planes.
Data Source
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AI summary
A cutting insert (2) comprises a peripheral side surface (30) which is parallel to a central axis (O) of a first end surface (10) and a second end surface (20). The peripheral side surface (30) comprises a first side surface (31) facing a first major cutting edge (11), a second side surface (32) facing a first wiper edge (12), and a third side surface (33) facing a first inner edge (13). A flank (311) of the first major cutting edge 11 and a flank (321) of the first wiper edge (12) are inclined such that the flank (311, 331) approaches the central axis (O) as it heads toward the first end surface (10). The flank (311) of the first major cutting edge (11) is located on a different plane from the first side surface (31). The flank (321) of the first wiper edge (12) is located on a different plane from the second side surface (32). Meanwhile, a flank of the first inner edge (13) is located on the same plane as the third side surface (33).