Double-Sided Cutting Insert With Segmented Relief Surfaces

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Solution Overview

Problem

Conventional double-sided cutting inserts with negative rake angles suffer from deteriorated machinability due to their design, leading to increased resistance and reduced performance in high-speed, high-feed, or high-depth cutting operations.

Innovation Solution

The improved double-sided cutting insert features lateral relief surfaces formed in three stages, including a first positive surface, a negative surface, and a second positive surface, which increase the rake angle and enhance machinability while maintaining stable coupling with the cutter body, by only the negative surfaces contacting the cutter body.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If the cutting insert is designed with negative rake angle to enable double-sided use, then the coupling stability is improved, but the machinability deteriorates

Engineering Contradiction:

Improvecoupling stabilityVSAvoidmachinability

Core Design Contradiction:

Stability of the object's compositionVSEase of operation

Solution Approach 1:

The lateral relief surface is segmented into three distinct stages: a first positive surface, a negative surface, and a second positive surface. This segmentation allows each surface to serve different functions - the positive surfaces provide machinability with proper rake angles, while the negative surface ensures stable coupling with the cutter body, thereby resolving the contradiction between coupling stability and machinability

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the lateral relief surface are given different geometric properties. The first and second positive surfaces have positive rake angles optimized for cutting performance, while the intermediate negative surface has a negative rake angle optimized for coupling. This local differentiation allows the insert to achieve both good machinability and stable coupling simultaneously

Inventive Principle:

Principle #3Local quality

2Productivity

If the cutting edge length is increased to enable deeper cuts, then the cutting depth capability is improved, but the resistance increases

Engineering Contradiction:

Improvecutting depth capabilityVSAvoidcutting resistance

Core Design Contradiction:

ProductivityVSForce

Solution Approach 1:

The invention changes the rake angle parameter from negative to positive on the cutting surfaces. Positive rake angles reduce the friction and resistance between the cutting edge and the workpiece, allowing for deeper cuts with reduced cutting forces, thereby improving productivity without proportionally increasing resistance

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS8876440B2Cutting insert

Publication Date: 2014.11.04 KORLOY

AI summary

A cutting insert, and more particularly, an improved double-sided cutting insert is provided, which provides improved machinability obtained due to increased rake angle, without compromising coupling state. The double-sided cutting insert includes a top surface, a bottom surface, a plurality of lateral relief surfaces connecting the top and bottom surfaces, and a cutting edge formed by the top and bottom surfaces and the plurality of lateral relief surfaces, in which one or more lateral relief surfaces of the plurality of lateral relief surfaces are formed into three stages in sequence which are a first positive surface, a negative surface and a second positive surface in a direction from the top surface to the bottom surface.