Single-Sided Cutting Insert Seating Structure Without Grinding
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Solution Overview
Problem
The existing manufacturing process of single-sided cutting inserts requires a polishing step to flatten the lower surface, which is costly and inefficient due to unevenness caused by adhesion and sintering reaction marks on the seating surface.
Innovation Solution
A cutting insert design featuring a pedestal protruding from the outer peripheral edge of the seating surface, which prevents contact with the sintering plate, eliminating the need for a grinding step and ensuring flatness, and allowing for stable mounting without rattling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the green compact is sintered on a sintering plate, then the cutting insert can be manufactured, but unevenness and adhesion marks are formed on the seating surface requiring additional polishing steps
Solution Approach 1:
The lower surface is segmented into two functional zones: a seating surface zone that remains flat and clean for mounting, and a pedestal zone that contacts the sintering plate. This segmentation allows the seating surface to avoid direct contact with the sintering plate, preventing adhesion marks while maintaining manufacturing efficiency.
Solution Approach 2:
The pedestal structure extracts the problematic contact function from the seating surface. By creating a protruding pedestal that extends beyond the seating surface, the sintering plate contact function is separated from the mounting function, allowing the seating surface to remain clean and flat without requiring post-sintering polishing.
2Manufacturing precision
If a polishing step is added to flatten the lower surface, then seating surface flatness is improved, but manufacturing cost and time increase
Solution Approach 1:
The pedestal structure is created during the sintering process itself, preliminarily establishing the flat seating surface geometry. This preliminary action during sintering eliminates the need for subsequent polishing operations, maintaining high manufacturing precision while improving productivity by removing unnecessary steps.
3Stability of the object's composition
If the entire lower surface contacts the sintering plate, then sintering support is adequate, but adhesion and unevenness occur on the seating surface
Solution Approach 1:
Different regions of the lower surface are assigned different qualities and functions: the seating surface region is designed to be flat and non-contacting for clean mounting, while the pedestal region is designed to contact the sintering plate for stable sintering support. This local differentiation eliminates adhesion marks on the seating surface while maintaining adequate sintering support.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design reduces manufacturing costs and ensures the flatness of the seating surface by eliminating the grinding step, while enabling stable clamping and optimal rake angles during tool operation.
Implementation Method 1
unevenness is formed on a portion (a lower surface on a seating surface side) of a cutting insert that comes into contact with a sintering plate due to adhesion of the contact reaction inhibitor
Implementation Method 2
the green compact for a cutting insert is sintered in a state of being placed on a sintering plate
Data Source
AI summary
This cutting insert is a plate-shaped cutting insert having a center line, and includes an upper surface that forms one surface of two surfaces facing each other in an axial direction along the center line; a lower surface that forms the other surface of the two surfaces facing each other; a side surface that connects the upper surface and the lower surface in the axial direction; and a mounting hole that passes through the cutting insert in the axial direction, in which the side surface extends obliquely inward in a radial direction perpendicular to the center line from the upper surface toward the lower surface in the axial direction.