Double-Sided Milling Insert Geometry for 90-Degree Shoulder Stability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional milling cutting inserts have limited independently useable cutting edges and stability when machining 90-degree shoulders, leading to reduced tool life and efficiency.
Innovation Solution
An indexable double-sided milling cutting insert with a unique geometry featuring multiple cutting edges, support edges, and symmetrical design, allowing for increased useable cutting edges and enhanced stability through precise seating surfaces, enabling smooth cutting of 90-degree shoulders and easy indexing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional single-sided milling cutting inserts are used, then the structure is simple, but the number of independently useable cutting edges is limited
Solution Approach 1:
The cutting insert is divided into two functional sides (top and bottom surfaces), each with its own cutting edges. This segmentation allows the insert to provide multiple independently useable cutting edges by utilizing both sides of the insert, effectively doubling the number of available cutting edges compared to conventional single-sided inserts.
Solution Approach 2:
The invention transitions from a single-sided (one-dimensional usage) insert to a double-sided (two-dimensional usage) insert. By adding cutting edges on the bottom surface in addition to the top surface, the insert utilizes the third dimension (depth/thickness) to provide additional cutting edges, thereby increasing versatility without proportionally increasing complexity.
2Reliability
If conventional milling cutting inserts are used, then the insert structure is simple, but stability during machining is insufficient
Solution Approach 1:
The insert geometry is segmented into multiple functional zones including top seat surface region, bottom seat surface region, support edges, and cutting edges. This segmentation allows each region to perform its specific function optimally, with seat surface regions providing stable mounting surfaces and support edges ensuring proper positioning, thereby enhancing overall stability.
Solution Approach 2:
Different regions of the insert are given different geometric qualities suited to their specific functions. The seat surface regions are designed with flat, stable surfaces for mounting, while the cutting edges are positioned and angled for optimal cutting performance. This local optimization of geometry enhances stability without requiring overall structural complexity.
3Productivity
If long main cutting edges are implemented, then cutting performance is improved, but the number of independently useable cutting edges may be reduced
Solution Approach 1:
The cutting insert is segmented into multiple cutting edges distributed across both top and bottom surfaces. Each cutting edge can be independently used, and the segmentation ensures that long main cutting edges on one side do not preclude the presence of additional cutting edges on the opposite side, maintaining both cutting performance and versatility.
Solution Approach 2:
By utilizing both top and bottom surfaces of the insert, the invention effectively adds another dimension to the arrangement of cutting edges. This allows long main cutting edges to be present on one surface while additional cutting edges are accommodated on the opposite surface, thereby maintaining both cutting performance and the number of independently useable edges.
Data Source
Figure 1
Figure 2~4
Figure 5~8
AI summary
An indexable double-sided milling cutting insert (1) is provided which comprises: a top surface (2), a bottom surface (3), a through-bore (5) coaxial to a first symmetry axis (X) intersecting the top surface (2) and the bottom surface (3), a plurality of side surfaces (4a, 4c), a median plane (YZ) extending perpendicular to the first symmetry axis (X) and virtually dividing the cutting insert into two halves, a first edge line (6a) at the intersection of the top surface with the plurality of side surfaces (4a, 4c), and a second edge line (6b) at the intersection of the bottom surface with the plurality of side surfaces (4a, 4c). Each of the first edge line (6a) and the second edge line (6b) comprise: first and second primary major corners (7a, 7b), first and second secondary major corners (8a, 8b), first and second minor corners (9a, 9b), first and second main cutting edges (10a, 10b), first and second secondary cutting edges (11a, 11b), and first and second support edges (12a, 12b). The top and bottom surfaces (2, 3) each comprise a first seat surface region (13a) extending to the first support edge (12a) and a second seat surface region (13b) extending to the second support edge (12b).