Cutting Insert Flank Geometry for Accurate Ramping Cuts
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Solution Overview
Problem
Existing cutting inserts face challenges in achieving high bottom-surface accuracy and efficient ramping while maintaining manufacturability, as they often require complex grinding processes and multiple passes due to uneven angles and undercuts, making them difficult to manufacture using dies.
Innovation Solution
A cutting insert design with a peripheral side surface perpendicular to the end surfaces, allowing the wiper edge and inner edge flanks to be formed on different planes, enabling efficient machining and manufacturing using a mold with reduced grinding passes, and featuring a major cutting edge with varying rake angles to manage cutting resistance and chip formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the flank of the wiper edge and the flank of the inner edge are located on the same plane, then ramping efficiency is improved, but bottom-surface accuracy deteriorates due to interference with the workpiece
Solution Approach 1:
The patent applies dimensionality change by positioning the flank of the wiper edge and the flank of the inner edge on different planes rather than the same plane. Specifically, the flank of the wiper edge is positioned on a first plane while the flank of the inner edge is positioned on a second plane that is different from the first plane. This spatial separation eliminates interference between the wiper edge and workpiece during ramping operations, thereby maintaining both high ramping efficiency and high bottom-surface accuracy.
2Ease of manufacture
If the side surface is used as a flank for all cutting edges, then the shape is simple for die manufacturing, but the angles are uneven requiring multiple grinding passes
Solution Approach 1:
The patent applies segmentation by dividing the side surface into multiple distinct planes, where each plane serves as a flank for specific cutting edges. The side surface is segmented such that the flank of the major cutting edge, the flank of the wiper edge, and the flank of the inner edge are located on different planes. This segmentation allows each flank to have its own optimized angle without requiring multiple grinding passes, as the angles are determined during the molding process itself.
3Manufacturing precision
If complex grinding processes are used to achieve accurate angles, then manufacturing precision is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent applies preliminary action by pre-forming the flank angles during the molding process rather than requiring subsequent grinding operations. The mold is designed with specific geometries that directly create the required flank angles for each cutting edge during insertion molding. This preliminary formation of angles eliminates the need for complex multi-pass grinding processes, reducing both manufacturing complexity and maintaining precision.
Data Source
AI summary
A cutting insert 2 comprises a peripheral side surface 30 which is parallel to a central axis O of a first end surface 10 and a second end surface 20. The peripheral side surface 30 comprises a first side surface 31 facing a first major cutting edge 11, a second side surface 32 facing a first wiper edge 12, and a third side surface 33 facing a first inner edge 13. A flank 311 of the first major cutting edge 11 and a flank 321 of the first wiper edge 12 are inclined such that the flank 311 and 321 approaches the central axis O as it heads toward the first end surface 10. The flank 311 of the first major cutting edge 11 is located on a different plane from the first side surface 31. The flank 321 of the first wiper edge 12 is located on a different plane from the second side surface 32. Meanwhile, a flank of the first inner edge 13 is located on the same plane as the third side surface 33.