Cutting Insert with Projecting Portions for Radial Rake Angle
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Solution Overview
Problem
Conventional cutting inserts face challenges in setting a suitable radial rake angle without reducing the size of the insert, which can lead to increased cutting resistance and reduced strength, and have limited design flexibility for round corner surfaces, affecting the formation of curved corner surfaces in grooves.
Innovation Solution
The cutting insert features projecting portions with cutting edges and round corner surfaces, allowing the radial rake angle to be set independently of the insert size, and enabling more design freedom for round corner surfaces by positioning these projections orthogonally to the insert body, with a length between projecting side surfaces shorter than the insert's diameter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the length between side surfaces of the cutting insert is reduced to set a small negative or positive radial rake angle, then the radial rake angle is improved, but the size of the cutting insert is reduced which significantly decreases the strength of the cutting insert
Solution Approach 1:
The cutting insert is divided into a body portion and multiple projecting portions. The projecting portions are positioned at outer positions of the insert body and each includes a cutting edge and a round corner surface. This segmentation allows the cutting edges to be positioned at optimal locations for achieving positive radial rake angles while maintaining the overall insert size and strength through the supporting body portion.
2Manufacturing precision
If the size of the round corner surface is increased to process curved corner surfaces, then the curved corner surface quality is improved, but the contact area between the abutment surface and side surfaces is reduced which hinders appropriate fixation
Solution Approach 1:
The round corner surfaces are positioned on the projecting portions rather than on the main body portion. This allows the round corner surfaces to be sufficiently large for processing curved corner surfaces of various sizes while the body portion maintains adequate contact area with the abutment surface for reliable fixation.
Solution Approach 2:
The round corner surfaces are positioned at elevated locations on the projecting portions, utilizing the vertical dimension. This allows large round corner surfaces to exist without reducing the horizontal contact area between the body portion and the abutment surface, thereby maintaining both curved corner surface quality and fixation reliability.
3Shape
If cutting edges are arranged at equal intervals around the central axis, then the symmetry is improved, but the design freedom for round corner surfaces is limited which affects the ability to process various groove sizes
Solution Approach 1:
The cutting insert is segmented into a body portion and multiple projecting portions positioned at outer positions. Each projecting portion can be independently designed with cutting edges and round corner surfaces. This segmentation provides design freedom to create round corner surfaces of various sizes and configurations while maintaining symmetry through the arrangement of multiple identical projecting portions around the central axis.
Data Source
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AI summary
An aspect of the present invention provides a cutting insert (1) including an insert body portion (13) and a plurality of projecting portions (15) provided integrally with the insert body portion (13) at outer positions of the insert body portion (13). The projecting portion (15) includes a cutting edge (23) and includes a projecting portion upper surface, a projecting portion lower surface, two projecting portion side surfaces, and a projecting portion side end surface extending therebetween. In the projecting portion (15), a round corner surface (33) extending between the projecting portion upper surface and the projecting portion side end surface is formed. The cutting edge (23) is formed along an intersecting ridge portion between the projecting portion side surface and the projecting portion upper surface, the round corner surface, and the projecting portion side end surface, so as to include a corner formed along an edge of the round corner surface and such that the projecting portion side surface serves as a rake face. The projecting portion (15) is designed such that a length between the two projecting portion side surfaces (29) is smaller than a diameter (IC) of an inscribed circle defined on a body portion upper surface.