Hexagonal Cutting Insert Geometry for Bidirectional Face Milling
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Solution Overview
Problem
Conventional cutting inserts face challenges with high cutting resistance and fracture risk during face milling processes, particularly due to uneven cutting edge configurations that limit bidirectional rotation and reduce cutting edge strength.
Innovation Solution
A cutting insert with a hexagonal shape featuring identical upper and lower surfaces, alternating major and minor corners with specific interior angles, and inclined cutting edges that distribute cutting forces effectively, allowing bidirectional rotation and enhancing fracture resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a straight line shaped cutting edge is used to enable bidirectional rotation, then rotation versatility is improved, but cutting edge strength deteriorates
Solution Approach 1:
The cutting edge is designed with a curved configuration instead of a straight line shape. Specifically, the cutting edge includes an arc-shaped portion that connects the major cutting edge and the corner cutting edge, forming a continuous curved profile. This curvature allows the cutting insert to maintain structural integrity and cutting edge strength while enabling bidirectional rotation capability.
2Productivity
If different cutting edge configurations are used for major and minor corners, then cutting performance is improved, but device complexity increases
Solution Approach 1:
The cutting insert employs asymmetric corner design where major corners have a first interior angle and minor corners have a second interior angle that is larger than the first. This asymmetric configuration optimizes cutting performance by providing different geometric characteristics for major and minor corners, while the continuous curved cutting edge connects these asymmetric corners in a unified manner.
Solution Approach 2:
The cutting edge is designed as a continuous curved structure that serves multiple functions: it forms major cutting edges for primary material removal, corner cutting edges for finishing, and maintains structural strength. This multi-functional curved cutting edge eliminates the need for separate cutting edge configurations, simplifying the overall design while maintaining high cutting performance.
Data Source
Figure 1(a)~1(b)
Figure 2(a)~2(c)
Figure 3(a)~3(b)
AI summary
A cutting insert of an embodiment of the present invention includes: a polygonal shaped upper surface; a lower surface being identical in shape to the upper surface; a side surface connected to each of the upper and lower surfaces; and an upper cutting edge located at the intersection of the upper surface and the side surface. The upper surface alternately includes three major corners, each having a first interior angle, and three minor corners, each having a second interior angle larger than the first interior angle. The upper cutting edge includes: a corner cutting edge; a minor cutting edge inclined toward the lower surface as separating from the corner cutting edge at a first inclination angle on the basis of a vertical plane perpendicular to a central axis extending between the upper and lower surfaces; and a major cutting edge inclined toward the lower surface as separating from the minor cutting edge at a second inclination angle larger than the first inclination angle on the basis of the vertical plane. The corner cutting edge, the minor cutting edge and the major cutting edge are located sequentially from a first major corner of the three major corners to each of first and second minor corners of the three minor corners, both of which are adjacent to the first major corner. A cutting tool with the cutting insert, and a method of manufacturing a machined product by using the cutting tool are also provided.