Indexable Drill Insert Fastening Surface Gradient
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Solution Overview
Problem
Existing indexable drills face challenges in securely fixing and easily mounting or separating cutting inserts without excessive coupling force, leading to material waste and rigidity issues during grinding processing.
Innovation Solution
The cutting insert features a unique fastening surface with a cylindrical shape and inclined central axis, along with a wrench groove and grinding reference surfaces, which allows for secure engagement and easy handling, minimizing material waste and maintaining rigidity during reuse.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If coupling force between the indexable drill and cutting insert is increased to secure fixation during high-speed rotation, then reliability of cutting insert fixation is improved, but ease of operation for mounting or separating cutting insert deteriorates
Solution Approach 1:
The fastening surface is designed with a gradient angle that allows dynamic adjustment of coupling force. During mounting, the gradient enables easy insertion with low resistance, while during high-speed rotation, the same gradient generates sufficient frictional force to secure the cutting insert firmly, thus resolving the contradiction between easy mounting and reliable fixation
Solution Approach 2:
The gradient angle of the fastening surface changes the physical parameters of contact between the cutting insert and indexable drill. This parameter change allows the coupling force to be optimized for both mounting ease and fixation reliability under different operational conditions
2Manufacturing precision
If conventional grinding processing is used on round bar material to manufacture cutting insert, then manufacturing precision is achieved, but loss of substance increases due to large number of parts disposed
Solution Approach 1:
The cutting insert body is pre-formed with the final desired shape through sintering before any grinding operations. This preliminary shaping action eliminates the need for extensive material removal, allowing only minimal grinding on specific surfaces like the fastening surface, thereby significantly reducing material waste while maintaining manufacturing precision
Solution Approach 2:
The manufacturing process changes from conventional machining of round bar to sintering of powdered metal, fundamentally altering the material form and production method. This parameter change in the manufacturing process enables near-net-shape production, minimizing the need for material removal and reducing waste
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables easy mounting and separation of cutting inserts, enhances coupling force, and reduces material waste by optimizing the grinding process, while maintaining the insert's rigidity even after regrinding.
Implementation Method 1
The self-fixing type indexable drill in the related art uses elasticity and frictional force of metal
Implementation Method 2
The self-fixing type indexable drill in the related art uses elasticity and frictional force of metal
Data Source
AI summary
The present disclosure relates to a cutting insert and an indexable drill. The cutting insert and the indexable drill according to the present disclosure are configured such that when the cutting insert is mounted on the indexable drill, the cutting insert is easily inserted into the indexable drill at the initial time, and strong coupling force is implemented between the indexable drill and the cutting insert at a point of time at which the cutting insert is completely mounted. In addition, the cutting insert, according to the present disclosure, has excellent rigidity, when compared to cutting inserts in the related art that perform identical/similar cutting processing, since a portion, which is weak in rigidity, is provided as a thick portion.