Cutting Insert Positioning and Load Reduction
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Solution Overview
Problem
Cutting inserts often need to be discarded when one side of the upper cutting edge is broken or deformed, even if the lower cutting edge and other sides are still in good condition, due to the design of grooves and position projections which prevent accurate positioning in the cutting tool.
Innovation Solution
A cutting insert design featuring upper and lower cutting load reducing portions and position setting portions on separate surfaces, allowing for reduced cutting load and accurate positioning even when edges are broken or deformed, with symmetrical and eccentric features to prevent common use of different shaped cutting edges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If grooves are formed on lateral surfaces to prevent common use of cutting edges, then positioning accuracy is improved, but the cutting insert must be discarded when any groove is broken
Solution Approach 1:
The positioning function is segmented from the cutting edges. Positioning protrusions are placed on lateral surfaces while cutting edges are on upper and lower surfaces, so that damage to cutting edges does not affect positioning grooves integrity, allowing independent evaluation of each component's condition
Solution Approach 2:
The positioning structure is moved from the upper surface to lateral surfaces, creating spatial separation between positioning grooves and cutting edges. This dimensional relocation ensures that broken cutting edges do not necessarily damage positioning grooves, enabling continued usability
2Productivity
If multiple grooves are formed to reduce cutting load and enable positioning, then cutting performance is improved, but complexity of the structure increases
Solution Approach 1:
The lateral surface is divided into multiple grooves that work together to provide both positioning and cutting load reduction functions, achieving multiple benefits through structured segmentation rather than adding separate components
Solution Approach 2:
The grooves on lateral surfaces serve dual purposes: positioning the cutting insert in the tool holder and reducing cutting load through chip breaking. This multi-functionality reduces the need for additional separate features
Data Source
AI summary
The objective of the present invention is to provide a cutting insert which reduces cutting load and can be accurately positioned at a coupling part of a cutting tool even if cutting edges are broken or deformed. To this end, the cutting insert of the present invention includes an upper surface, a lower surface, a plurality of lateral surfaces connecting the upper surface with the lower surface, and a plurality of upper cutting edges formed between the plurality of lateral surfaces and the upper surface. In addition, the cutting insert coupled with the coupling part of the cutting tool includes: first and second upper cutting load reducing portions formed on the upper surface and provided at each side coming in contact with first and second upper cutting edges of the plurality of upper cutting edges facing each other so as to reduce the cutting load; and a one side position setting portion provided on a first lateral surface of the plurality of lateral surfaces not coming in contact with the first and second upper cutting edges so as to set the position of the cutting insert in the coupling part.