Cutting Insert Mount Structure for Stable Face Milling Attachment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional cutting inserts used in face milling processes face issues with deformation during firing, leading to unstable attachment due to variations in shape and environmental factors, which affects the stability of the mount surface and increases the risk of detachment.
Innovation Solution
The cutting insert design features a hexagonal shape with alternating top portions and a concave part, ensuring that the mount surface is less likely to contact the holder at the central axis, thereby improving attachment stability by using the outer edges as fixing points, and a concave part to reduce contact area and enhance fixing force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a flat mount surface is molded on the insert, then the insert can be attached to the holder, but deformation during firing causes the mount surface to contact at unintended positions, deteriorating attachment stability
Solution Approach 1:
The patent applies asymmetry by designing the mount surface with alternating high and low portions rather than a uniform flat surface. The high portions are positioned at specific locations to serve as contact points with the holder, while the low portions create a concave structure. This asymmetric distribution of contact points compensates for firing-induced deformations by ensuring that the highest points maintain proper alignment and contact with the holder, thereby improving attachment stability despite manufacturing variations
Solution Approach 2:
The patent implements local quality by creating distinct regions on the mount surface with different heights and properties. The high portions are specifically designed to be the contact points with the holder, while the low portions form a concave area that prevents unwanted contact. This localized differentiation ensures that only specific predetermined positions make contact with the holder, maintaining attachment stability even when overall surface deformation occurs during firing
2Reliability
If the mount surface contacts the holder at the central axis, then attachment is achieved, but this increases the risk of detachment due to deformation
Solution Approach 1:
The patent extracts or removes the central axis area from being a contact point by creating a concave portion at the center of the mount surface. This concave area is positioned lower than the surrounding high portions, effectively taking out the central region from the contact interface. By doing so, the design eliminates the harmful effect of central axis contact that would be susceptible to deformation-induced detachment, while maintaining stable attachment through the peripheral high portions
3Reliability
If a large contact area is provided between mount surface and holder, then attachment is secure, but this increases the risk of deformation affecting contact stability
Solution Approach 1:
The patent segments the mount surface contact area into multiple discrete high portions rather than providing a single large continuous contact area. These high portions are distributed at specific locations around the mount surface. This segmentation approach maintains secure attachment through multiple contact points while reducing the impact of deformation, as each small high portion can independently maintain proper contact despite overall surface variations
Data Source
Figure 1
Figure 2(a)~2(b)
Figure 3(a)~3(b)
AI summary
A cutting insert (1) of an embodiment of the present invention includes an upper surface (2), a lower surface (3), a side surface (4) connected to each of the upper surface (2) and the lower surface (3), and an upper cutting edge (5) located at an intersection of the upper surface (2) and the side surface (4). The lower surface (3) includes a mount part having alternately three first top portions (311) spaced a distance a away from a central axis (S1) extending between the upper and lower surfaces (2, 3) and three second top portions (312) spaced a distance b away from the central axis (S1) in a bottom view. The mount part further has a concave part including at least the central axis (S1). The second top portions (312) are located closer to the upper surface (2) than the first top portions (311). A cutting tool (10) with the cutting insert (1), and a method of manufacturing a machined product by using the cutting tool (10) are also provided.