Double-Sided Milling Insert With Chip Deflectors 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 chips scratching the inclined side surfaces, leading to reduced useful life and improper mounting when these surfaces are worn.

Innovation Solution

The design incorporates chip deflecting members on the main side faces to redirect chips away from the inclined surfaces, enhancing the durability of inactive cutting edges and ensuring stable mounting by configuring inclined surfaces as both relief and abutment surfaces in different working positions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If the cutting insert uses inclined side surfaces for relief in working positions, then the cutting edges can be properly relieved and positioned, but the inactive cutting edges suffer erosion and damage from chips scratching the inclined surfaces

Engineering Contradiction:

Improverelief surface precisionVSAvoidinactive cutting edge integrity

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

A chip deflecting member is introduced as an intermediary element between the chips and the inclined side surfaces. This deflecting member redirects chips away from the inclined surfaces, preventing direct contact and erosion, while allowing the inclined surfaces to maintain their relief function for active cutting edges.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The solution converts the harmful effect of chips scratching the inclined surfaces by using the chip flow itself to carry the chips away from the vulnerable areas. The chip deflecting member utilizes the natural chip flow direction to redirect chips, turning the chip movement from a harmful scratching action into a beneficial evacuation path that protects the inactive cutting edges.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

2Duration of action of moving object

If the cutting insert is designed with multiple working positions, then the insert can be reused longer by turning to new positions, but the inclined surfaces used for mounting in one position become eroded and cause improper mounting in subsequent positions

Engineering Contradiction:

Improveinsert service lifeVSAvoidmounting precision

Core Design Contradiction:

Duration of action of moving objectVSManufacturing precision

Solution Approach 1:

The chip deflecting member serves as a protective intermediary that preserves the integrity of the inclined side surfaces across multiple working positions. By preventing chip-induced erosion during each working position, the deflecting member ensures that the inclined surfaces maintain their precise geometry for proper mounting in subsequent positions, thereby extending the insert's service life.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The chip deflecting member provides preliminary protection to the inclined surfaces before they can be eroded by chips. This preventive measure is in place from the beginning of each working position, stopping erosion before it can accumulate and compromise the mounting precision in future positions.

Inventive Principle:

Principle #10Preliminary action

3Stability of the object's composition

If the inclined side surfaces are used as abutment surfaces for mounting, then the insert can be securely positioned, but erosion of these surfaces leads to improper mounting and reduced reliability

Engineering Contradiction:

Improveinsert mounting stabilityVSAvoidmounting reliability

Core Design Contradiction:

Stability of the object's compositionVSReliability

Solution Approach 1:

The chip deflecting member acts as a protective barrier between the chips and the inclined abutment surfaces. This intermediary structure prevents direct chip contact with the mounting surfaces, maintaining their stability and reliability across multiple insert positions and operations.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The chip deflecting member provides beforehand protection by being positioned to intercept chips before they can reach and erode the inclined abutment surfaces. This prior cushioning effect prevents the gradual degradation that would otherwise compromise mounting stability and reliability.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Data Source

PatentUS12605777B2Double-sided cutting insert and milling tool

Publication Date: 2026.04.21 SECO TOOLS AB

AI summary

A double-sided cutting insert for milling includes first and second major faces, a peripheral surface arranged between the major faces and including a first main side face, a first main cutting edge formed at an intersection between the first main side face and the first major face, a second main cutting edge formed at an intersection between the first main side face and the second major face, first and second inclined side surfaces, which are formed on the first main side face and which are inclined towards each other to form a depression on the first main side face, and a chip deflecting member formed on the first main side face as a protrusion across the depression and which includes a chip deflecting surface configured to deflect chips, which hit the first main side face, away from the depression.