Cutting Insert Assembly With Stepped Flank for Stable Mounting
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Solution Overview
Problem
Existing cutting inserts suffer from reduced stability and increased risk of separation from the tool holder due to varying flank surface widths and clearance angles, leading to vibration and damage during cutting processes, especially under poor cutting conditions.
Innovation Solution
A cutting insert design with a stepped sub-cutting edge flank surface and enlarged support surfaces, combined with a tool holder pocket configuration featuring locking jaws, ensures stable mounting by maintaining contact area and preventing separation during cutting impacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a large setting angle is applied in the positive direction to increase the clearance angle of the sub-cutting edge flank surface, then sharpness is improved, but the lower surface area decreases, resulting in reduced stability when mounting the cutting insert to the tool holder
Solution Approach 1:
The sub-cutting edge flank surface is divided into two distinct surfaces: a first sub-cutting edge flank surface and a second sub-cutting edge flank surface. This segmentation allows each surface to serve a specific function - the first surface provides the necessary clearance angle for sharpness, while the second surface maintains adequate contact area with the tool holder for mounting stability.
Solution Approach 2:
Different regions of the sub-cutting edge flank surface are given different geometric properties. The first sub-cutting edge flank surface has a larger clearance angle for improved sharpness, while the second sub-cutting edge flank surface is positioned to ensure sufficient contact area with the tool holder, creating local quality variations that resolve the contradiction.
2Manufacturing precision
If the width of the first flank surface of the main cutting edge is not constant, then the clearance angle can be optimized, but the area of the second flank surface in contact with the cutting tool is reduced, resulting in deteriorating stability when mounting the cutting insert to the tool holder
Solution Approach 1:
The main cutting edge flank surface is segmented into a first flank surface and a second flank surface. The first flank surface can have variable width for optimized clearance angle, while the second flank surface is specifically designed to maintain constant or sufficient width to ensure stable contact with the tool holder during mounting.
Solution Approach 2:
The first main cutting edge flank surface is allowed to have non-constant width for clearance angle optimization, while the second main cutting edge flank surface maintains adequate width specifically at the contact region with the tool holder. This local quality differentiation resolves the contradiction between clearance angle optimization and mounting stability.
3Ease of manufacture
If the sub-cutting edge flank surface is a single surface with constant clearance angle, then manufacturing is simplified, but the area of the seating surface in contact with the tool holder is reduced, resulting in deteriorating stability when mounting the cutting insert to the tool holder
Solution Approach 1:
Instead of using a single sub-cutting edge flank surface, the invention segments it into two surfaces. This segmentation increases manufacturing complexity slightly but significantly improves mounting stability by providing adequate contact area between the cutting insert and tool holder while still maintaining manufacturability.
Data Source
AI summary
A cutting insert of the present invention includes an upper surface, a lower surface, a side surface, a cutting edge, and a mounting hole penetrating the upper surface and the lower surface, in which the cutting edge includes a main cutting edge, a corner cutting edge extending from the main cutting edge, and a sub-cutting edge extending from the corner cutting edge, the side surface includes a main cutting edge flank surface and a sub-cutting edge flank surface, the main cutting edge flank surface includes a first main cutting edge flank surface extending from the main cutting edge, and a second main cutting edge flank surface extending from the lower surface, the sub-cutting edge flank surface includes a first sub-cutting edge flank surface extending from the sub-cutting edge, and a second sub-cutting edge flank surface extending from the lower surface, the first sub-cutting edge flank surface and the second sub-cutting edge flank surface together form a stepped portion, and the second sub-cutting edge flank surface protrudes from an imaginary plane extending from the first sub-cutting edge flank surface.