Cylindrical-Segment Cutting Insert for Lower Burr Thickness
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Solution Overview
Problem
Conventional cutting inserts with straight edges generate undesirable burrs during machining, leading to increased deburring time and costs, and existing cutting insert designs do not effectively reduce burr formation.
Innovation Solution
A cutting insert with a substantially horizontal cylindrical segment shape featuring convex top and bottom cutting edges, a flat side, and a hole at the center of the flat side, which reduces burr formation by altering the cutting edge geometry and stress distribution during machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional straight cutting edges are used, then the cutting insert structure is simple and easy to manufacture, but burr formation increases significantly
Solution Approach 1:
The patent applies curvature to the cutting edge by introducing a convex side with a defined radius of curvature (R1) that transitions smoothly from the top surface to the bottom surface. This curved geometry modifies the stress distribution during cutting, reducing burr formation while maintaining manufacturing feasibility through standard machining operations.
Solution Approach 2:
The patent changes the geometric parameters of the cutting insert by introducing specific curvature radii (R1 for the convex side, R2 for the transition surface) and defined angles (α for the top surface, β for the bottom surface). These parameter modifications optimize the cutting action to minimize burr formation while preserving ease of manufacture.
2Manufacturing precision
If burr formation is reduced through additional processing, then manufacturing precision improves, but productivity decreases due to increased deburring time
Solution Approach 1:
The patent implements preliminary action by designing the cutting insert with built-in burr-reducing geometry before the cutting operation occurs. The convex side and transition surface are pre-configured with specific curvatures and angles that prevent excessive burr formation during machining, eliminating or minimizing the need for subsequent deburring operations and thereby maintaining high productivity.
3Object-generated harmful factors
If the cutting edge geometry is modified to reduce burrs, then burr thickness decreases, but the cutting insert design complexity increases
Solution Approach 1:
The patent applies local quality by modifying only specific regions of the cutting insert geometry. The convex side with radius R1 and the transition surface with radius R2 are localized modifications to the cutting edge area, while the rest of the insert structure remains simple and unchanged. This targeted approach reduces burr thickness without significantly increasing overall design complexity.
4Manufacturing precision
If deburring operations are performed manually to remove burrs, then edge quality improves, but labor intensity and time consumption increase
Solution Approach 1:
The patent implements self-service by designing the cutting insert to automatically minimize burr formation through its inherent geometry. The convex side and transition surface work together during the cutting process to produce cleaner edges without requiring external deburring operations, thereby eliminating time loss and reducing labor intensity while maintaining edge finish quality.
Data Source
AI summary
A cutting insert of a substantially horizontal cylindrical segment shape may include top and bottom surfaces having a circular segment shape. The cutting insert may include a convex side and a flat side. The cutting insert may include a top cutting edge which is formed where the convex side and the top surface meet, and a bottom cutting edge which is formed where the convex side and the bottom surface meet. The cutting insert may include a hole extending from the convex side towards the flat side. The hole may be positioned at a center of a surface of the flat side.