High-Feed Cutting Insert Geometry for Rigidity and Low Vibration
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Solution Overview
Problem
Conventional tangential cutting inserts face issues with rigidity, edge strength, and increased cutting load during high feed machining, leading to vibrations and uneven cut surfaces due to excessive entering angles and negative radial rake angles.
Innovation Solution
A high feed cutting insert design featuring a main surface, sub-surface, short and long side surfaces, and strategically positioned cutting edges forming obtuse and acute angles, with curved and inclined shapes to minimize negative radial rake and enhance edge strength, allowing for sufficient entering angles without compromising tool rigidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the cutting insert is mounted at excessive angles to provide entering angle and back taper, then the entering angle requirement is met, but the rigidity of the bottom part of the cutting tool is lowered
Solution Approach 1:
The cutting insert employs an asymmetric geometry where the front surface is configured at a specific angle relative to the main cutting edge, and the side surfaces are positioned at different orientations. This asymmetric design allows the insert to achieve the required entering angle (5-15 degrees) while maintaining proper mounting orientation, thereby preserving the rigidity of the cutting tool bottom part without excessive mounting angles
Solution Approach 2:
The invention introduces angular dimensionality through the front surface angle and side surface orientations. By utilizing multiple angular dimensions (front surface angle, side surface angle, mounting angle), the system achieves the entering angle requirement through geometric configuration rather than excessive mounting inclination, thus maintaining tool rigidity
2Reliability
If the entering angle is decreased to prevent breakdown, then the cutting insert stability is improved, but large radial force and increased vibrations are generated
Solution Approach 1:
The invention optimizes the entering angle parameter within the specific range of 5-15 degrees, balancing stability and force generation. Additionally, the front surface angle and side surface angle parameters are configured to modify the force distribution during cutting, reducing excessive radial forces while maintaining insert stability and preventing breakdown
3Ease of manufacture
If the main cutting edge and sub-cutting edge have straight line shape, then the manufacturing is simplified, but the cutting edge strength is lower and contact load with workpiece is larger
Solution Approach 1:
The cutting edges are configured with curved geometries instead of straight lines. The main cutting edge and sub-cutting edge feature arc-shaped profiles that increase edge strength and reduce contact load with the workpiece. This curvature also improves chip flow characteristics while maintaining manufacturability through standard grinding and shaping processes
4Device complexity
If the radial rake angle is inclined towards negative direction, then the cutting insert geometry is simplified, but the cutting load is increased and vibration is generated
Solution Approach 1:
The invention optimizes the radial rake angle parameter by configuring the side surfaces at specific angles relative to the radial direction. This parameter optimization ensures the radial rake angle remains within a range that prevents excessive negative inclination, thereby reducing cutting load and minimizing vibrations while maintaining geometric simplicity
Data Source
AI summary
The present disclosure's technical object is to provide a high feed cutting insert capable of providing a sufficient entering angle while ensuring rigidity of a cutting tool's bottom part. For this, the high feed cutting insert of the present disclosure comprises a short cutting edge provided on a boundary portion between a main surface and a short side surface, a long cutting edge provided on a boundary portion between the main surface and a long side surface, two ascending corner cutting edges connecting the short cutting edge and the long cutting edge, and placed on one diagonal position, and two descending corner cutting edges placed on the other diagonal position and having the height lower than that of the ascending corner cutting edges, wherein the short cutting edge and the long cutting edge, when viewed towards the main surface, form an obtuse angle while the ascending corner cutting edges are interposed therebetween and form an acute angle while the descending corner cutting edges are interposed therebetween.