Double-Sided Cutting Inserts With Axial Chip Guidance for Helical Milling
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Solution Overview
Problem
The existing design of helical milling cutters with overlapping cutting inserts restricts the free space between adjacent inserts, impairing chip formation and evacuation, leading to potential damage and erosion.
Innovation Solution
A double-sided cutting insert with specific chip guiding surfaces and inclined main cutting edges, allowing increased space for chip formation and evacuation, reducing damage to inactive edges and erosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If cutting inserts are arranged in overlapping positions to form a long cutting line, then the cutting capability is improved, but the free space for chip formation and evacuation is reduced
Solution Approach 1:
The cutting insert is designed with chip guiding surfaces that extend in the axial direction (another dimension) to guide chips away from the restricted radial space. This dimensional approach allows chips to be directed along the axial path rather than requiring sufficient radial clearance, thereby resolving the contradiction between overlapping insert arrangement and chip evacuation space
Solution Approach 2:
The chip guiding surfaces act as intermediary elements between the cutting edges and the chip flow path. These surfaces mediate the chip formation process by providing a controlled path for chip evacuation, preventing chips from interfering with the overlapping insert arrangement while maintaining the long cutting line configuration
2Length of stationary object
If cutting inserts are arranged in overlapping positions, then the cutting line length is increased, but the risk of chip jamming and edge damage increases
Solution Approach 1:
By introducing axial chip guidance through inclined surfaces, the system redirects chip flow into the axial dimension, preventing chips from accumulating in the restricted radial space between overlapping inserts. This maintains the long cutting line while eliminating chip jamming risks
Solution Approach 2:
The chip guiding surfaces are designed in advance to preemptively direct chips away from potential jamming zones before chips can cause damage. The inclined surfaces create a predetermined escape path that prevents chip accumulation and subsequent edge damage
Data Source
Figure 1a~1b
Figure 1c~1d
Figure 1e~1g
AI summary
A double-sided cutting insert (1) for use in a helical milling cutter with rectangular basic shape and four different working positions. A peripheral surface (10) extends around the cutting insert between two major faces (2, 3) and has two longer main side faces (11, 12) and two shorter main side faces (13, 14). A main cutting edge (31-34) is formed at an intersection between each longer main side face (11, 12) and each major face (2, 3). An inclined chip guiding surface (41-44) extends between each shorter main side face (13, 14) and each major face (2, 3). Each chip guiding surface intersects an abutment surface (5a, 5b) of the adjacent major face on both sides of a longitudinal centre plane of the cutting insert. The invention also relates to a helical milling cutter comprising a plurality of such cutting inserts.