Indexable Face Milling Insert for Stable Positioning After Sharpening

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Solution Overview

Problem

Face milling cutters face positioning failures after polishing and are not adaptable for both face cutting milling and wiper face milling on the same cutter head, leading to inefficiencies and reduced precision.

Innovation Solution

An indexable face milling cutting insert with a prismoid shape, featuring multiple positioning side surfaces, a larger upper plane, and a positioning bottom surface, allowing for rotation and adjustment to form specific angles, enabling flexible mounting on a cutter head with adaptable retaining slots for both cutting and polishing functions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If the alloy substrate is polished to restore cutting edge sharpness, then the cutting edge sharpness is improved, but the positioning side surface is deformed causing positioning failure

Engineering Contradiction:

Improvecutting edge sharpnessVSAvoidpositioning accuracy

Core Design Contradiction:

Measurement precisionVSReliability

Solution Approach 1:

The insert body is divided into distinct functional surfaces: a positioning bottom surface for primary positioning, multiple positioning side surfaces for secondary positioning, and a larger upper plane for cutting operations. This segmentation allows the positioning surfaces to be protected from polishing damage while the cutting edge can be restored.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The insert body is pre-designed with a larger upper plane area than the positioning bottom surface area, creating a geometric structure where the positioning surfaces are inherently protected. This preliminary geometric arrangement ensures that during polishing, only the cutting edge portion is affected while positioning surfaces remain intact.

Inventive Principle:

Principle #10Preliminary action

2Manufacturing precision

If two separate face milling cutters are used for face cutting milling and wiper face milling, then each function can be optimized, but the device complexity and mounting requirements increase

Engineering Contradiction:

Improvecutting precisionVSAvoidcutter head structure

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The insert body is designed as a universal component that can perform both face cutting milling and wiper face milling functions. By rotating the insert body to different angular positions, the same insert can achieve different cutting angles suitable for different milling operations, eliminating the need for separate dedicated inserts for each function.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The insert body can be dynamically rotated to different angular positions on the cutter head, allowing the cutting edge to form different angles with the workpiece surface. This dynamic adjustment capability enables the same insert to adapt to both face cutting milling (with larger angles) and wiper face milling (with smaller angles) requirements.

Inventive Principle:

Principle #15Dynamics

3Loss of substance

If the cutting material is laminated on a small alloy substrate, then the cost is reduced, but the positioning stability and service life decrease

Engineering Contradiction:

Improvematerial costVSAvoidpositioning stability

Core Design Contradiction:

Loss of substanceVSStability of the object's composition

Solution Approach 1:

The solution transitions from a two-dimensional positioning approach (using only the bottom surface) to a three-dimensional positioning system that utilizes the bottom surface, multiple side surfaces, and the larger upper plane. This dimensional expansion provides more positioning reference surfaces, improving stability without requiring a larger substrate.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The insert uses a composite structure with an alloy substrate providing mechanical strength and positioning surfaces, while the cutting material (such as polycrystalline diamond or cubic boron nitride) is laminated on the upper plane for cutting operations. This composite approach optimizes both cost and performance.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS11311949B2Indexable face milling cutting insert and face milling cutting head using the cutting insert

Publication Date: 2022.04.26 BEIJING WORLDIA DIAMOND TOOLS

AI summary

Disclosed is an indexable face milling cutting insert which comprises an insert body and a cutting body laminated on an upper surface of the insert body, and the insert body comprises multiple positioning side surfaces, an upper plane, and a positioning bottom surface; a projection of an edge of the positioning bottom surface, or an extension line thereof, on a rake face is intersected with a corresponding edge of the rake face, or an extension line thereof, to form a surface deflection angle and multiple flank faces are arranged between the rake face and the multiple positioning side surfaces, so as to avoid damaging the positioning side surfaces when a cutting edge is sharpened, thereby ensuring stability and long-term effect of a positioning reference, and a face cutting milling and a wiper face milling are applicable to a same face milling insert retaining slots.