Cutting Insert Flutes for Milling Sharpness and Edge Strength
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Solution Overview
Problem
Existing cutting inserts for milling cutters face challenges in maintaining sharpness, increasing blade edge strength, and maximizing corner usage due to the need for tilting, which reduces sharpness and increases costs.
Innovation Solution
A cutting insert with two polygonal main surfaces and multiple side faces, featuring flutes along cutting edges that provide clearance, allowing for reduced axial and radial rake angles and increased tilt angles to maintain sharpness and strength without compromising blade edge integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the cutting insert is tilted to provide clearance angle for the front flank face, then clearance is provided, but the axial rake becomes blunt and sharpness is reduced
Solution Approach 1:
The invention transitions from a two-dimensional clearance provision method (tilting the entire insert) to a three-dimensional localized solution by providing relief on specific faces (top and bottom faces) of the insert. This allows clearance to be provided in the radial direction without affecting the axial rake angle, thus maintaining sharpness while eliminating interference.
Solution Approach 2:
Instead of tilting the entire cutting insert uniformly, the invention applies relief only to specific locations (top and bottom faces) where interference occurs. This localized approach preserves the sharpness of the cutting edge by maintaining the original axial rake angle while providing clearance only where needed for the front flank face.
2Manufacturing precision
If the rake face is tilted by a large amount to compensate for bluntness, then sharpness is improved, but the strength of the blade edge is reduced
Solution Approach 1:
The invention moves the clearance provision from the axial dimension (tilting the rake face) to the radial dimension (relief on top and bottom faces). This allows sharpness to be maintained through proper axial rake angle while blade edge strength is preserved by avoiding excessive tilt that would thin the blade edge.
3Object-affected harmful factors
If the top and bottom faces have parallelogram shapes to provide clearance angle, then clearance is provided, but the number of corners used is halved and costs increase
Solution Approach 1:
The invention applies relief only to specific faces (top and bottom faces) rather than changing the overall shape of all faces. This localized approach allows the insert to maintain a square configuration with four usable corners, whereas a parallelogram configuration would only allow two corners to be used, thereby reducing tool costs and increasing productivity.
Data Source
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AI summary
Forming cutting inserts for milling cutters that meet both the demands of providing good sharpness and cutting edge tip strength and the demand of increasing the number of corners used according to use is a matter to be achieved. A cutting insert, used for a milling cutter, which includes two polygonal main surfaces that are opposite each other and a plurality of side faces and whose main surfaces are rake faces, whose side faces are flank faces, and whose ridge lines at positions where the main surfaces and the side faces cross each other are used as cutting edges include two major side surfaces that are opposite each other and a plurality of minor side surfaces that are formed continuously with the major side surfaces. A mounting hole is provided at the two major side surfaces in a direction in which the mounting hole extends therethrough, and areas of the two major side surfaces are greater than those of the main surfaces. The major side surfaces and the minor side surfaces are provided with flutes along entire regions of the cutting edges.