Cutting Insert with Cylindrical Recesses for Multi-Edge Rotation
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Solution Overview
Problem
Existing indexable cutting inserts lack the ability to efficiently expose multiple cutting edges to a workpiece without requiring new inserts when existing edges wear out, leading to inefficiencies and increased costs.
Innovation Solution
A cutting insert design featuring a body with a cylindrical main surface and radially inward recess surfaces, allowing multiple cutting edges to be formed by intersections, which can be rotated to extend beyond the tool holder's periphery, enabling extended use and reduced waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If a cutting insert has only one cutting edge, then the structure is simple, but the insert must be replaced frequently when the cutting edge wears out
Solution Approach 1:
The cutting insert body is divided into multiple segments by creating several recess surfaces (first, second, third, fourth recess surfaces) that intersect with the main surface, forming multiple distinct cutting edges. This segmentation allows the insert to provide multiple cutting edges from a single body structure.
Solution Approach 2:
The cutting insert is designed with multiple cutting edges (first, second, third, and fourth cutting edges) on a single insert body, enabling the same insert to perform cutting operations multiple times by rotating to expose different cutting edges. This multi-functionality eliminates the need to replace the insert after a single cutting edge wears out.
2Productivity
If a cutting insert has multiple cutting edges, then replacement frequency is reduced, but the manufacturing complexity increases
Solution Approach 1:
The insert body is segmented into multiple functional zones by creating recess surfaces at specific intervals around the cylindrical main surface. The first and second recess surfaces form cutting edges on one side, while the third and fourth recess surfaces form cutting edges on the opposite side, allowing systematic manufacturing of multiple cutting edges.
Solution Approach 2:
The recess surfaces are arranged asymmetrically around the cylindrical main surface, with the first and second recess surfaces positioned differently from the third and fourth recess surfaces. This asymmetric arrangement allows for optimized chip flow paths and cutting geometry while maintaining multiple cutting edges.
3Reliability
If cutting edges are positioned to extend beyond tool holder periphery, then cutting performance is improved, but the insert design becomes more complex
Solution Approach 1:
The main surface of the cutting insert is designed as a cylindrical (curved) surface rather than a flat surface. This curvature allows cutting edges formed by the intersection of recess surfaces with the main surface to naturally extend beyond the periphery of the tool holder when mounted, improving cutting performance without requiring complex additional structures.
Solution Approach 2:
The cutting edges are positioned in three-dimensional space by forming recess surfaces that intersect the cylindrical main surface at various angles and positions. This spatial arrangement allows cutting edges to extend beyond the tool holder periphery in the radial direction while maintaining structural integrity of the insert body.
Data Source
AI summary
A cutting insert includes a body having a first surface, a second surface, and an intermediate surface. The intermediate surface includes a generally cylindrical main surface and at least one recess surface extending radially inwardly from the main surface, the main surface and the recess surface extending between the first surface and the second surface. Cutting edges are defined by intersections between the main surface and the recess surface.