Hexahedral Cutting Insert with Curved Side Faces
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Solution Overview
Problem
Conventional milling cutting inserts with square plates cause high cutting resistance, lead to machining quality deterioration due to discontinuities, and result in shortened service life and scratches on machined surfaces.
Innovation Solution
A hexahedral cutting insert with flat top and bottom faces, inclined side faces, and corner surfaces, featuring main cutting edges with central and outer edge portions, undercuts, and screw holes for reduced cutting resistance and enhanced strength, allowing for stable machining and lower manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If square plate type cutting inserts are used for deep groove machining, then the cutting insert can be mounted on milling cutter, but high cutting resistance occurs and machining quality deteriorates
Solution Approach 1:
The cutting insert employs curved side faces with rounded corners instead of sharp corners and flat surfaces. The side faces include upper and lower rounded portions that gradually change the cross-sectional shape, reducing cutting resistance and preventing scratches on the machined surface while maintaining effective cutting capability.
Solution Approach 2:
The cutting insert uses an asymmetric hexahedral shape with different upper and lower cross-sectional areas. The upper cross-sectional area is smaller than the lower cross-sectional area, creating a tapered form that reduces material removal volume and cutting resistance while maintaining structural integrity at the base.
2Manufacturing precision
If multiple cutting inserts are mounted in axial and circumferential directions, then continuous machining without unmachined portions is achieved, but scratches occur on overlapped portions and service life shortens
Solution Approach 1:
The rounded corners and curved side faces eliminate sharp edges that cause scratches during overlapping passes. The gradual curvature transition ensures smooth material removal without abrupt edge contacts, preventing surface defects even when multiple inserts are used in阵列 configuration.
Solution Approach 2:
The insert design preemptively addresses potential scratch issues by incorporating rounded features before machining begins. The pre-formed curved surfaces ensure that no sharp corners will contact the workpiece during operation, preventing scratches before they can occur.
3Ease of manufacture
If square plate type cutting inserts are used, then simple mounting is achieved, but fewer cutting edges are available and service life is shortened
Solution Approach 1:
The hexahedral insert is designed with multiple usable cutting edges by strategically positioning and rounding corners. Each side face with rounded portions creates additional effective cutting edges, allowing the single insert to be used multiple times with different edges, thereby extending service life without complicating the manufacturing process.
4Productivity
If corner edges are formed on hexahedral insert, then eight main cutting edges are provided, but manufacturing precision requirements increase
Solution Approach 1:
The rounded corners and curved side faces are designed with radii that are practical for molding operations. By optimizing the curvature radius to be sufficiently large, the insert maintains eight effective cutting edges while remaining manufacturable with conventional molding precision, avoiding the need for extremely tight tolerances.
Data Source
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AI summary
The present invention discloses a hexahedral insert having top and bottom faces and two pairs of opposing side faces with main cutting edges formed on the borders of the top and bottom faces to the side faces and a screw hole passing through each central portion of the top and bottom faces, wherein the top and bottom faces are flat planes parallel to each other; each of the side faces consecutively from top to bottom includes an upper land portion, an upper inwardly-inclined portion, a flat support surface, a lower inwardly-inclined portion, and a lower land portion; and each of two adjacent side faces has a corner surface therebetween which forms corner edges on the borders to the top and bottom faces. The insert of the present disclosure enhances the cutting power by reducing cutting resistance, prevents scratches on a machined surface, and the manufacturing cost is much cheaper.