Double-Sided Cutting Insert With Through-Opening Design
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Solution Overview
Problem
Conventional single-sided cutting inserts used in milling operations have limited cutting edges, reduced strength due to defined clearance angles, and are prone to damage during high-speed and rapid feed cutting, limiting their lifetime and productivity.
Innovation Solution
A cutting insert design with increased stiffness, featuring multiple cutting edges, including corner, major, and minor cutting edges, along with boundary cutting edges, and chip breakers, arranged in a specific geometry to enhance cutting efficiency and stability, allowing for rapid feed cutting and extended tool life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a conventional single-sided cutting insert is used, then the structure is simple, but the number of cutting edges is limited and the strength is reduced
Solution Approach 1:
The cutting insert transitions from a single-sided structure to a double-sided structure with cutting edges on both the upper and lower surfaces. This dimensional change effectively doubles the number of usable cutting edges while maintaining structural integrity through the through-opening design that reinforces the insert body.
Solution Approach 2:
The cutting insert is divided into multiple cutting edges (corner cutting edges, major cutting edges, and minor cutting edges) distributed across both surfaces. This segmentation allows multiple cutting edges to be utilized sequentially, extending tool life while each individual edge maintains adequate strength through the optimized geometry.
2Productivity
If rapid feed cutting is implemented, then productivity increases, but the cutting insert may be damaged due to reduced strength
Solution Approach 1:
By utilizing both upper and lower surfaces for cutting edges, the insert can sustain higher cutting forces and speeds. The dual-sided design distributes wear across more edges, allowing rapid feed cutting to be performed repeatedly without compromising durability.
Solution Approach 2:
The corner side surfaces are formed with rounded shapes rather than sharp edges, and corner cutting edges incorporate curved geometries. This curvature distributes stress more evenly during rapid feed cutting, preventing stress concentration and improving reliability under high-productivity conditions.
3Duration of action of stationary object
If multiple cutting edges are added, then tool life extends, but the structure becomes more complex
Solution Approach 1:
The through-opening design enables symmetric replication of cutting edges on both surfaces. This dimensional approach multiplies the number of usable edges without proportionally increasing complexity, as the lower surface edges mirror the upper surface geometry.
Solution Approach 2:
The cutting insert is designed to function on both upper and lower surfaces, with each surface providing multiple cutting edges for different operations. This multi-functionality extends tool life while using a single, integrated structure rather than multiple separate components.
4Ease of operation
If clearance angles are defined in side surfaces, then cutting performance is improved, but the strength of the cutting insert is reduced
Solution Approach 1:
Clearance angles are applied selectively to specific side surfaces where they are needed for cutting performance, while other surfaces maintain stronger geometries. The corner side surfaces use rounded shapes rather than sharp clearance angles, locally optimizing for strength where stress concentration would occur.
Solution Approach 2:
Rounded corner side surfaces replace sharp clearance angle geometries in critical stress areas. This curvature maintains adequate clearance for chip flow while distributing stresses more evenly, preserving insert strength without sacrificing cutting performance.
Data Source
AI summary
A cutting insert for high-efficiency cutting is disclosed. The cutting insert includes an upper surface (110a), a lower surface (HOb), side surfaces (114) and corner side surfaces (116), which connect the side surfaces to each other. A circular opening is formed through the central portions of the upper and lower surfaces. In the cutting insert, cutting edges are formed by respective junctions between one of the upper and lower surfaces and the side surfaces and between one of the upper and lower surfaces and the corner side surfaces. The cutting edges comprise three corner cutting edges (122), six major cutting edges (124), which extend from opposite ends of the corner cutting edges towards the neighbor corner cutting edges, and three minor cutting edges (126), which are connected between the major cutting edges. Furthermore, the cutting edges may be formed on both the upper surface and the lower surface.