Double-Sided Milling Insert With Chip Deflection for Edge Protection
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Solution Overview
Problem
Existing double-sided cutting inserts suffer from erosion and damage to inactive cutting edges due to chip impact, leading to reduced lifespan and improper mounting when worn edges are repositioned.
Innovation Solution
A double-sided cutting insert with inclined side surfaces and chip deflecting members that redirect chips away from vulnerable areas, enhancing durability and ensuring stable repositioning by acting as both relief and abutment surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If chips are allowed to follow their natural trajectory during milling, then chip removal is simple, but inactive cutting edges suffer from erosion and damage
Solution Approach 1:
A chip deflecting member is introduced as an intermediary element between the chips and the inactive cutting edge. This member actively redirects chips away from the vulnerable inactive cutting edge, preventing erosion and damage while maintaining simple chip removal pathways.
Solution Approach 2:
The chip deflecting member is positioned in advance to counteract the harmful trajectory of chips before they can reach the inactive cutting edge. By preemptively redirecting chips, the system prevents erosion and damage before they occur.
2Productivity
If the cutting insert is used for multiple working positions, then productivity increases, but the inactive cutting edge becomes vulnerable to chip impact and erosion
Solution Approach 1:
The chip deflecting member serves as a protective intermediary that shields the inactive cutting edge from chip impact during multi-position operation, enabling the insert to be safely reused across multiple working positions without erosion damage.
Solution Approach 2:
The system converts the potentially harmful chip trajectory into a beneficial configuration where chips are redirected along a controlled path that avoids the inactive cutting edge, allowing multi-position usage to proceed without damage.
3Reliability
If inclined side surfaces are added to form relief surfaces, then cutting edge performance improves, but device complexity increases
Solution Approach 1:
The inclined side surfaces serve multiple functions simultaneously: they form relief surfaces for active cutting edges, provide abutment surfaces for stable positioning, and work in conjunction with the chip deflecting member to protect inactive edges. This multi-functionality reduces the need for additional separate components.
Solution Approach 2:
The chip deflecting member is integrated with the inclined side surfaces, combining the relief surface function and chip deflection function into a unified structural arrangement, thereby reducing overall device complexity while maintaining both functions.
Data Source
Figure 1a~1b
Figure 1c~1d
Figure 1e~1f
AI summary
A double-sided cutting insert for use in milling, comprising: - first and second major faces (2, 3); - a peripheral surface (10) arranged between said major faces (2, 3) and comprising a first main side face (11); - a first main cutting edge (21) formed at an intersection between the first main side face and the first major face; - a second main cutting edge (22) formed at an intersection between the first main side face and the second major face; - first and second inclined side surfaces (31, 32), which are formed on the first main side face (11) and which are inclined towards each other to form a depression (D1) on the first main side face; and - a chip deflecting member (50), which is formed on the first main side face as a protrusion across said depression (D1) and which comprises a chip deflecting surface (51) configured to deflect chips that hit the first main side face away from the depression.