Double-Sided Milling Insert Geometry for Low-Vibration Finishing
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Solution Overview
Problem
Existing cutting inserts experience suboptimal performance at small and intermediate cutting depths, leading to vibrations during milling operations, especially with long tool overhangs, which negatively impacts surface finish quality.
Innovation Solution
A cutting insert design featuring a major wiper edge that slopes downward from the corner edge toward the major cutting edge, reducing cutting loads and vibrations, along with a double-sided configuration that maintains smooth cutting performance even at negative axial tipping-in angles, and includes a chip formation surface with a larger width inside the corner edges for enhanced surface finishing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional cutting edge shapes are used, then chip removal is effective, but cutting forces become large causing vibrations during milling, especially with long tool overhangs
Solution Approach 1:
The cutting insert is divided into multiple functional zones: a major cutting edge for primary material removal, a minor cutting edge for finishing, and wiper edges for surface quality. This segmentation allows each zone to perform its specific function optimally, reducing overall cutting forces and vibrations while maintaining effective chip removal.
Solution Approach 2:
Different regions of the cutting insert have different geometries and functions. The major cutting edge has a specific rake angle for efficient cutting, the minor cutting edge has a different geometry for finishing, and the wiper edges have unique profiles for surface quality. This local differentiation optimizes performance at each location while minimizing harmful vibrations.
2Manufacturing precision
If conventional wiper edges are used for surface finishing, then surface quality improves, but cutting performance at small and intermediate cutting depths becomes suboptimal
Solution Approach 1:
The cutting insert is designed with multiple edges that can serve different functions. The major cutting edge handles primary material removal at various depths, the minor cutting edge provides finishing capability, and the wiper edges ensure surface quality. This multi-functionality allows the insert to perform optimally across a wide range of cutting depths from small to large.
3Ease of manufacture
If single-sided cutting inserts are used, then manufacturing is simpler, but versatility for different operations is limited
Solution Approach 1:
The cutting insert employs an asymmetric design with a double-sided configuration where each side has differently oriented cutting edges and wiper edges. This asymmetry allows the insert to be used for various operations including contouring, copy milling, shoulder milling, and ramping by simply changing the insert orientation, thereby enhancing versatility without significantly complicating manufacturing.
Data Source
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AI summary
An indexable cutting insert (201) for a milling tool, comprising: - an upper side (202); - a lower side (203); - a side surface (204) connecting the upper and lower sides; - at least two identical upper cutting edges (205), each comprising a chip removing major cutting edge (210) and a minor cutting edge (211) extending on opposite sides of a corner edge (209), a major wiper edge (212) extending between the corner edge and the major cutting edge, and a minor wiper edge (213) extending between the corner edge and the minor cutting edge, wherein, as seen in a top view, the major cutting edge and the major wiper edge form an obtuse inner angle of less than 180° and, as seen in a side view, the major wiper edge slopes downward from the corner edge toward the major cutting edge, and the major cutting edge has a first portion (219) sloping downward from the major wiper edge and a second portion (220) which extends in parallel with the upper side.