Cutting Insert Geometry for Accurate Mounting and More Blades
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional cutting inserts used in five-axis machining face challenges in accuracy during attachment to cutting tool bodies and in increasing the number of blades without expanding the insert width.
Innovation Solution
A cutting insert design featuring an upper and lower surface with curved cutting edges, a through hole, and inclined end surfaces, allowing for stable attachment and increased rigidity, while enabling more blades to be mounted without increasing the insert width.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a positive shape is used to ensure sharpness, then cutting edge sharpness is improved, but attachment accuracy to the tool body deteriorates
Solution Approach 1:
The cutting insert is divided into functionally distinct surfaces: a positive-shaped cutting edge portion for sharpness and a separate flat reference surface for accurate attachment. This segmentation allows each surface to optimize its specific function without compromising the other.
Solution Approach 2:
Different surfaces of the cutting insert have different geometric qualities tailored to their specific functions: the cutting edge has a positive shape for sharpness while the reference surface has a flat geometry for attachment accuracy. Each local area has the quality needed for its purpose.
2Productivity
If the number of corners in one cutting insert is increased, then the number of blades is increased, but the insert width becomes large making it difficult to mount more blades
Solution Approach 1:
The cutting edges are arranged in a three-dimensional configuration utilizing both the upper and lower surfaces of the insert. This vertical dimensionality allows multiple cutting edges to be packed into a compact width, increasing the number of usable blades without expanding the insert width.
3Productivity
If the insert width is kept small to increase the number of blades, then the number of mountable blades is increased, but the rigidity of the insert clamp during cutting is reduced
Solution Approach 1:
The inclined end surfaces create a wedge-like geometric form that efficiently distributes clamping forces. This curved/angled geometry provides mechanical advantage, maintaining clamp rigidity even in a compact insert design that accommodates multiple cutting edges.
Data Source
AI summary
Provided is a structure for improving accuracy in attaching a cutting tool to a body and making it possible to increase the number of blades while the cutting tool is mounted on the body. A cutting insert 1 includes: an upper surface 10 that has a shape with a lengthwise direction LD and a widthwise direction SD; a lower surface that is located opposite to the upper surface 10; a peripheral side surface 30 that is formed so as to connect the upper surface 10 and the lower surface; cutting edges 51 and 52 that are respectively formed on an intersecting ridge line of the upper surface 10 and the peripheral side surface 30, and on an intersecting ridge line of the lower surface and the peripheral side surface 30, and each have a curved ridge line that extends in a lengthwise direction thereof; and a through hole 60 that penetrates from the upper surface 10 to the lower surface. End surfaces 31 and 32 located in the lengthwise direction LD of the upper surface 10 and the lower surface, of the peripheral side surface 30, are respectively inclined with respect to the upper surface 10 and the lower surface, and are parallel to each other. A reference surface 33 that is located opposite to the cutting edges 51 and 52, of the peripheral side surface 30, is a flat surface that is orthogonal to the upper surface 10 and the lower surface.