Double-Sided Cutting Insert Geometry for Deep Ramping Milling

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Solution Overview

Problem

Existing cutting tools for milling operations, particularly for ramping operations, lack efficient designs that can handle large cutting depths and provide adequate clearance and flexibility for various workpiece orientations, leading to suboptimal performance.

Innovation Solution

A double-sided cutting insert with diagonally opposed raised and lowered corners, featuring convexly curved cutting edges and a tangential retention mechanism, which allows for improved cutting performance and flexibility during milling and ramping operations by optimizing edge geometry and retention in a rotary cutting tool.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Length of moving object

If conventional cutting insert designs are used for ramping operations, then the tool can perform basic milling, but it lacks the capability to handle large cutting depths effectively

Engineering Contradiction:

Improvecutting depthVSAvoidcutting performance

Core Design Contradiction:

Length of moving objectVSReliability

Solution Approach 1:

The cutting insert features diagonally opposed raised corners and diagonally opposed lowered corners, creating an asymmetric geometry that enables effective ramping operations at large cutting depths. The raised corners provide structural support while the lowered corners facilitate chip evacuation and reduced interference during deep ramping cuts.

Inventive Principle:

Principle #4Asymmetry

2Adaptability or versatility

If standard cutting insert geometry is used, then the insert is simple to manufacture, but it provides inadequate clearance and flexibility for various workpiece orientations

Engineering Contradiction:

Improveflexibility for workpiece orientationsVSAvoidinsert geometry

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

Different regions of the cutting insert have specialized geometries: raised corners with specific cutting edges for structural support and cutting, lowered corners for clearance and chip evacuation, and concave clearance depressions in corner side surfaces. This local differentiation provides adaptability for various workpiece orientations while maintaining manufacturability.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The insert incorporates three-dimensional features including concave clearance depressions that extend from lowered corner cutting edges toward raised corners on opposite end surfaces. This adds a depth dimension to the clearance geometry, providing flexibility for different workpiece orientations without excessive complexity.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Reliability

If conventional cutting edge geometry is used, then the insert is easy to manufacture, but it results in increased wear and suboptimal cutting performance

Engineering Contradiction:

Improvecutting performanceVSAvoidedge geometry

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The raised corner cutting edges and lowered corner cutting edges follow curved paths along the peripheral side surface. This curvature optimizes chip flow and cutting performance while distributing stresses more evenly during ramping operations, reducing wear. The curved geometry is achievable through standard forming processes.

Inventive Principle:

Principle #14Spheroidality (Curvature)

4Object-generated harmful factors

If simple cutting insert design is used, then manufacturing is straightforward, but chip evacuation is poor and wear is increased

Engineering Contradiction:

Improvechip evacuationVSAvoidinsert structure

Core Design Contradiction:

Object-generated harmful factorsVSDevice complexity

Solution Approach 1:

The lowered corner cutting edges are positioned within concave clearance depressions that extend toward raised corners on opposite end surfaces. This geometry converts what would be potential interference zones into beneficial clearance areas that facilitate chip evacuation and reduce heat buildup, directly addressing chip removal issues.

Inventive Principle:

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

Data Source

PatentUS11027342B2Double-sided cutting insert having diagonally opposed raised corners and diagonally opposed lowered corners, and rotary cutting tool

Publication Date: 2021.06.08 ISCAR LTD

AI summary

A cutting insert has two opposing end surfaces interconnected by a peripheral side surface, the peripheral side surface having two major side surfaces and two minor side surfaces. Major edges are formed at the intersection of the major side surfaces and the end surfaces. Each end surface has two diagonally opposed raised corners and two diagonally opposed lowered corners with respect to a median plane, each raised corner adjoining one of the major edges at a first major point and each lowered corner adjoining one of the major edges at a third major point. In a major side view, each major edge has an associated first imaginary straight line containing its first and third major points, and an elevated edge portion located on one side of the first imaginary straight line. The cutting insert is removably secured in a rotary cutting tool.