Double-Sided Cutting Insert Geometry for Stable Support and Edge Strength

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Solution Overview

Problem

Existing cutting inserts face challenges in stable support and edge strength, particularly along the diagonal line where thickness is reduced, leading to concentrated stress at thicker apexes, making it difficult to achieve sufficient edge strength and axial rake angle.

Innovation Solution

A cutting insert design featuring first and second end surfaces with inclined surfaces that decrease in distance from a central axis, allowing for rotational symmetry and stable support through contact with tool body surfaces, enhancing edge strength and axial rake angle by distributing cutting forces effectively.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If the cutting insert is reduced in thickness along the diagonal line to achieve a compact shape, then the overall form factor is improved, but the stability of support in the diagonal direction deteriorates

Engineering Contradiction:

Improvethickness of cutting insertVSAvoidsupport stability in diagonal direction

Core Design Contradiction:

Volume of moving objectVSStability of the object's composition

Solution Approach 1:

The cutting insert employs non-uniform thickness distribution with thicker regions at the apexes and intermediate portions, and thinner regions along the diagonal lines. This local variation in thickness provides both compact overall dimensions and sufficient local strength for stable support during cutting operations.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The cutting insert features an asymmetric thickness profile where the thickness varies along different diagonals and across different regions of the insert. This asymmetric design allows optimization of both support stability and cutting performance by concentrating material where needed and reducing it where less critical.

Inventive Principle:

Principle #4Asymmetry

2Strength

If the thickness is increased at the apexes to improve edge strength, then the strength at cutting edges is improved, but stress concentration increases making it difficult to achieve sufficient edge strength

Engineering Contradiction:

Improveedge strength at apexesVSAvoidstress concentration at apexes

Core Design Contradiction:

StrengthVSStress or pressure

Solution Approach 1:

The cutting insert employs curved transition surfaces between the thicker apex regions and the thinner diagonal regions. These curved transitions eliminate sharp corners and stress concentration points, distributing stresses more evenly while maintaining the thicker sections needed for edge strength.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The insert features localized thickening at the apexes and intermediate portions with controlled thickness transitions. This local quality variation provides sufficient material for edge strength while avoiding excessive stress concentration through proper thickness gradation.

Inventive Principle:

Principle #3Local quality

3Adaptability or versatility

If the cutting insert is designed with rotational symmetry to allow cutting with either surface, then the versatility of the cutting tool is improved, but the complexity of achieving sufficient axial rake angle and strength increases

Engineering Contradiction:

Improveability to cut with either surfaceVSAvoidcomplexity of achieving axial rake angle and strength

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The cutting insert is designed with rotational symmetry about the axis perpendicular to the diagonal plane, enabling the same insert to be used for cutting operations from either end surface. This universal design allows flexibility in mounting orientation while maintaining consistent cutting performance through symmetric geometry.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The cutting insert employs a composite structure combining regions of different thicknesses and material properties within a single component. This composite design achieves both the symmetric versatility for dual-surface cutting and the localized strength requirements through integrated geometry optimization.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS11198186B2Cutting insert and cutting tool

Publication Date: 2021.12.14 TUNGALOY CORP

AI summary

There is provided a cutting insert which is capable of cutting by using either one of both surfaces and is stably supported by a tool body. Each of a first end surface and a second end surface of a cutting insert includes a first inclined surface which is inclined from a diagonal line by which a corner portion connecting a first peripheral side surface and a second peripheral side surface and a corner portion connecting a third peripheral side surface and a fourth peripheral side surface are joined toward a corner portion connecting the first peripheral side surface and the fourth peripheral side surface such that a distance to an imaginary plane decreases, and a second inclined surface which is inclined from the diagonal line toward a corner portion connecting the second peripheral side surface and the third peripheral side surface such that a distance to the imaginary plane decreases.