Double-Sided Indexable Cutting Insert with Six Cutting Portions
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Solution Overview
Problem
Existing double-sided indexable cutting inserts for milling operations lack the capability to efficiently perform operations with six cutting portions, which limits their effectiveness in metal cutting, especially in ramping and milling tasks.
Innovation Solution
A double-sided indexable cutting insert with six cutting portions, featuring a central axis, end surfaces with primary and secondary apexes, and a peripheral surface with specific cutting edges and clearance surfaces, allowing for efficient metal cutting and ramping operations by providing adequate clearance and chip flow management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a double-sided indexable cutting insert with six cutting portions is designed for milling operations, then the productivity and operational capabilities are improved, but the device complexity increases due to the need for specific clearance surfaces and curved portions
Solution Approach 1:
The cutting insert is divided into six distinct cutting portions, each with its own first cutting edge, second cutting edge, and tip cutting edge. This segmentation allows multiple cutting operations to be performed with a single insert, improving productivity while maintaining manageable complexity through modular design
Solution Approach 2:
The invention introduces curved portions that extend from the major portion of the first cutting edge and curve away from the mid-plane in the direction along the central insert axis. This three-dimensional configuration provides adequate clearance for ramping operations and enhances chip flow management, resolving the contradiction between operational capability and structural complexity
2Reliability
If clearance surfaces are added to provide adequate clearance for cutting edges, then the cutting performance is improved, but the manufacturing complexity increases
Solution Approach 1:
Clearance surfaces are provided locally at specific positions on the peripheral surface, extending from the second cutting edges toward the mid-plane. This localized approach ensures adequate clearance where needed for reliable cutting performance while minimizing the overall manufacturing complexity by not requiring clearance surfaces throughout the entire insert structure
Solution Approach 2:
The curved portions that extend from the major portion of the first cutting edge and curve away from the mid-plane provide the necessary clearance geometry for ramping operations. The curved configuration achieves reliable cutting performance while being manufacturable through standard forming processes
3Adaptability or versatility
If six cutting portions are provided on each end surface, then the versatility and operational capabilities are enhanced, but the ease of operation decreases due to precise positioning requirements
Solution Approach 1:
The end surfaces feature three primary apexes and three secondary apexes in an asymmetric arrangement, with cutting portions positioned at the primary apexes. This asymmetric geometry provides inherent positioning features that guide the insert into the correct orientation within the tool holder, enhancing ease of operation while maintaining six cutting portions for versatility
Solution Approach 2:
The insert abutment surfaces on abutment planes are positioned to engage with corresponding features in the tool holder before the cutting edges engage the workpiece. This preliminary action ensures precise positioning and orientation of the insert, making operation easier while maintaining the versatility of six cutting portions
Data Source
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AI summary
A cutting insert (100) having two end surfaces (102) and a peripheral surface (104), the end surfaces (102) located on opposite sides of a mid-plane (P), each end surface (102) having three primary apexes (106) and three secondary apexes (108). Six cutting portions (110) are formed along the intersection of the peripheral surface (104) and the end surfaces (102). Each cutting portion (110) has a first cutting edge (112) and a second cutting edge (114) extending transversely thereto. A ramping cutting edge (118) extends between the second cutting edge (114) of each cutting portion (110) and the first cutting edge (112) of an adjacent cutting portion (110). The peripheral surface (104) has a clearance surface (120) extending from each of the second cutting edges (114) towards the mid-plane (P). The abutment planes (AP) of the insert (100) are parallel to the mid-plane (P). Each of the first cutting edges (112) lies between an adjacent abutment plane (AP) and adjacent primary apex (106).