Cutting Insert Geometry for Four Edges in Thin Small-Diameter Tools

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Solution Overview

Problem

Existing cutting tools with multiple cutting inserts struggle to maintain a thin profile while allowing for the use of multiple cutting edges, making it difficult to machine small diameters effectively.

Innovation Solution

A cutting insert and tool design featuring a hexagonal first cutting face, trapezoidal second cutting faces, and adjustable mounting seats that allow for the use of four cutting edges by switching between two first cutting edges and two second cutting edges, with wedge angles less than 90 degrees to reduce cutting resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If the cutting insert is made thick to accommodate multiple cutting edges by turning over, then four cutting edges can be used by switching, but the thickness increases making it difficult to machine small diameters

Engineering Contradiction:

Improvenumber of usable cutting edgesVSAvoidthickness of cutting insert

Core Design Contradiction:

Adaptability or versatilityVSLength of moving object

Solution Approach 1:

The cutting insert is divided into functionally distinct regions: a first cutting face with two first cutting edges for rough machining, and second cutting faces with two second cutting edges for finish machining. This segmentation allows each region to be optimized for its specific function while maintaining overall compactness, enabling four cutting edges to be used without increasing thickness.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of utilizing the thickness dimension to accommodate multiple cutting edges (which would require turning the insert over), the patent arranges four cutting edges in a planar configuration on different faces of the insert. The first cutting edges are on the first cutting face, and the second cutting edges are on the second cutting faces, allowing all four edges to be accessed without increasing insert thickness.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Object-affected harmful factors

If wedge angles of cutting edges are reduced to less than 90 degrees, then cutting resistance is reduced, but the structural integrity and strength of the cutting edge may be compromised

Engineering Contradiction:

Improvecutting resistanceVSAvoidstrength of cutting edge

Core Design Contradiction:

Object-affected harmful factorsVSStrength

Solution Approach 1:

Different regions of the cutting insert have different geometric characteristics optimized for their specific functions. The first cutting edges have wedge angles less than 90 degrees optimized for rough machining with higher material removal rates, while the second cutting edges have different geometric characteristics suited for finish machining. This local optimization allows reduced cutting resistance where needed while maintaining overall structural integrity.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS20240390988A1Cutting insert, body, and cutting tool

Publication Date: 2024.11.28 TUNGALOY CORP

AI summary

The invention provides a cutting insert, a body, and a cutting tool that can limit thickness while allowing a total of four cutting edges to be used by switching. A cutting insert 30 to be mounted on a body 20 of a cutting tool 10 includes: a first cutting face 411 hexagonal in shape by being made up of one end face 110 of a pair of end faces 110 and 120 opposed to each other; a pair of first cutting edges 311 and 312 formed along a pair of sides 111 and 114 opposed to each other among sides marking off the first cutting face 411; second cutting faces 421 and 422 trapezoidal in shape by being made up of a pair of side faces 210 and 220 opposed to each other; and second cutting edges 321 and 322 each formed along one 210 or 220 of sides marking off each of the second cutting faces 421 and 422.