Double-Sided High Feed Milling Insert for Low-Power Chip Evacuation
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Solution Overview
Problem
Existing high feed milling methods require complex production processes and high costs for cutting inserts with angled clearance surfaces, leading to increased power requirements and potential for vibrations and impaired chip removal rates.
Innovation Solution
A double-sided milling insert with a trigonal shape and convex clearance surfaces, featuring a curved cutting edge with straight portions, a rake face, and a bisector plane for reduced power requirements and improved chip evacuation, allowing for efficient machining with a favorable radial angle and low production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If angled clearance surfaces are used in cutting inserts, then cutting performance is improved, but production complexity and cost increase
Solution Approach 1:
Instead of creating complex angled clearance surfaces on the insert itself, the patent inverts the approach by using a simple planar insert with a toolholder that has angled pockets. The angle is achieved through the toolholder geometry rather than the insert geometry, simplifying insert manufacturing while maintaining the desired cutting angle.
Solution Approach 2:
The toolholder acts as an intermediary between the simple planar insert and the workpiece. It provides the angled mounting surface that translates the simple insert geometry into the required angled cutting configuration, eliminating the need for complex insert surfaces.
2Ease of manufacture
If straight cutting edges are used, then manufacturing is simplified, but power requirements increase and chip removal is impaired
Solution Approach 1:
The patent applies curvature to the cutting edge by providing a curved surface on the toolholder pocket that contacts the insert. This curved contact surface creates an optimized cutting edge geometry that reduces power requirements and improves chip removal while maintaining manufacturing simplicity through the toolholder design rather than complex insert geometry.
3Reliability
If complex pressing and machining steps are used, then cutting insert function is optimized, but production time and cost increase
Solution Approach 1:
The patent segments the complex geometry requirements between the simple insert and the angled toolholder pocket. The insert remains a simple planar component that can be manufactured quickly, while the toolholder contains the complex angled geometry, allowing optimized cutting function without complex insert manufacturing steps.
Solution Approach 2:
The optimized cutting geometry is copied from the toolholder pocket design to the insert through the mounting interface. The pocket geometry defines the cutting angle and edge shape, eliminating the need for complex pressing and machining of the insert itself.
Data Source
Figure 1A~1C
Figure 1B~1E
Figure 1F~3
AI summary
A double-sided milling insert (30;30') for high feed milling of metal workpieces with a trigonal basic shape and comprising upper (31) and lower (32) faces facing in opposite directions and convex clearance surfaces (33) extending between the upper (31) and lower (32) faces. Each one of the faces comprises a recessed support surface (34A,34B), the support surfaces (34A,34B) being substantially parallel to each other, and having a cavity (35) therein for receiving a fastening means. Intersections of the convex clearance surfaces (33) with the upper and lower faces (34A,34B) form convex cutting edges (37A,37B;37A',37B') when seen in a plan view (fig. 1A) and a rake face (38) is provided adjacent the convex cutting edges (37A,37B,37a',37b'). Each convex cutting edge (37A,37B,37a',37b') is concave when seen in a side view (fig. 1b) and comprises a substantially straight cutting edge portion (39A,39B;39A',39B') on each side of a curved cutting edge portion (40A,40B;40A',40B') when seen in a plan view (fig 1a). A milling tool with a plurailty of such inserts and a method of high feed milling using this tool are also disclosed.