Disposable Cutting Insert with Short Curved Blade Edge

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Solution Overview

Problem

Conventional internal boring processes require multiple cutting tools to achieve a mirror-like surface finish, leading to increased manufacturing time, cost, and surface imperfections due to the need for additional tools like internal microller burnishing tools.

Innovation Solution

A disposable cutting insert with a polygonal body and a short curved blade edge design that allows for a two-tool process, eliminating the need for internal microller burnishing tools by achieving a mirror-like surface roughness through optimized cutting edge geometry and feed rates.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a conventional boring cutter with linear side blade edge and front blade edge is used, then the cutting operation can be performed, but the surface roughness cannot achieve mirror-like finish (Rmax≤0.1μm) and additional internal microller burnishing tool is required

Engineering Contradiction:

Improvesurface roughnessVSAvoidnumber of cutting tools

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent applies curvature to the cutting edge by forming a short curved blade edge connecting the side blade edge and front blade edge. This curved geometry with optimized radius allows the cutting insert to achieve mirror-like surface finish (Rmax≤0.1μm) directly during boring operation, eliminating the need for additional burnishing tools and resolving the surface roughness limitation of conventional linear-edge cutters

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The patent merges the functions of multiple cutting tools (coarse boring cutter, fine boring cutter, and internal microller burnishing tool) into a single boring cutter equipped with the optimized disposable cutting insert. The combined design enables one tool to perform both roughing and finishing operations, reducing device complexity from three tools to one

Inventive Principle:

Principle #5Merging (Combining)

2Manufacturing precision

If internal microller burnishing tool is used to achieve mirror-like surface, then surface roughness can be reduced, but manufacturing time increases due to tool changing

Engineering Contradiction:

Improvesurface roughnessVSAvoidmanufacturing time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent combines roughing and finishing capabilities into a single boring cutter with the optimized cutting insert. The short curved blade edge geometry enables the same tool to achieve both material removal and mirror-like surface finish in one continuous operation, eliminating tool changing time and preventing surface blackening from bit accumulation

Inventive Principle:

Principle #5Merging (Combining)

3Manufacturing precision

If internal microller burnishing tool is used to achieve mirror-like surface, then surface roughness can be reduced, but manufacturing cost increases

Engineering Contradiction:

Improvesurface roughnessVSAvoidmanufacturing cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent employs a disposable cutting insert with optimized short curved blade edge geometry that can achieve mirror-like surface finish. This disposable insert replaces expensive, reusable internal microller burnishing tools, reducing manufacturing cost while maintaining the ability to produce Rmax≤0.1μm surface quality

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent merges multiple cutting functions into one tool, eliminating the need to purchase and maintain separate internal microller burnishing equipment. The integrated solution reduces total manufacturing cost by consolidating tooling requirements

Inventive Principle:

Principle #5Merging (Combining)

4Manufacturing precision

If internal microller burnishing tool is used repeatedly, then mirror-like surface can be achieved, but bits accumulate in roll beads and blacken the manufacturing surface

Engineering Contradiction:

Improvesurface roughnessVSAvoidsurface blackening

Core Design Contradiction:

Manufacturing precisionVSObject-generated harmful factors

Solution Approach 1:

The patent uses a disposable cutting insert that is replaced after a single use or limited number of operations. This eliminates the accumulation of bits in roll beads that causes surface blackening, as the insert is discarded before significant bit accumulation can occur and affect surface quality

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent extracts the problematic roll bead structure from the cutting system. By using a disposable insert without roll beads or with minimal bit accumulation design, the harmful extrusion and adhesion of bits onto the workpiece surface is eliminated

Inventive Principle:

Principle #2Taking out (Extraction)

Data Source

PatentUS7431541B2Disposable cutting insert for boring cutter

Publication Date: 2008.10.07 CHANG

AI summary

A disposable cutting insert for a boring cutter can reduce the roughness of a cut surface and achieve a mirror-like surface effect. The disposable cutting insert has a long curved blade edge, and the radius vertex of the long blade edge is deviated slightly from an external side of a vertex of the radius of cutting edge. A short curved blade edge is formed between the radius arc vertex and the radius arc vertex of the cutting edge. The vertical distance of the short curved blade edge is greater than the feed rate. The cutting edge cuts the work piece and the short curved blade edge can scrape a small size of material precisely for scraping the peak cut by the cutting edge and lower the height of the peak, so as to lower the surface roughness, and produce a mirror-like surface for an internal periphery of a bored hole.