Indexable Cutting Insert with Positive Axial Rake Angle
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Solution Overview
Problem
Double-side indexable cutting inserts with multiple cutting edges, when mounted with negative axial rake angles, fail to fully utilize the greater cutting forces they can withstand when oriented tangentially, limiting their depth of cut.
Innovation Solution
The design of an indexable cutting insert comprising three components with a first component, a mirror-symmetric third component, and a second component disposed between them, where the cutting edges define a positive axial rake angle, allowing for a more aggressive depth of cut by rotating the components relative to each other to optimize cutting performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If cutting inserts are mounted with negative axial rake angle for cutting clearance, then cutting edges can engage the workpiece, but the inserts cannot take advantage of greater cutting forces when tangentially mounted
Solution Approach 1:
The patent inverts the conventional negative axial rake angle design by implementing a positive axial rake angle. This inversion allows the cutting insert to simultaneously achieve proper cutting edge engagement and full utilization of the insert's structural strength when tangentially mounted, resolving the contradiction between force capacity and operational effectiveness
Solution Approach 2:
The patent changes the axial rake angle parameter from negative to positive. This parameter change enables the cutting insert to maintain structural integrity while providing adequate cutting clearance, allowing the insert to withstand greater cutting forces and achieve more aggressive depth of cut
2Productivity
If cutting edges are extended beyond inscribed circle dimension for aggressive depth of cut, then cutting performance improves, but structural integrity may be compromised
Solution Approach 1:
The patent extends cutting edges in the axial dimension beyond the inscribed circle of the insert body. This dimensional extension allows aggressive depth of cut while the positive axial rake angle provides structural support, enabling the extended edges to maintain strength during cutting operations
3Adaptability or versatility
If multiple cutting edges are provided on double-side indexable inserts, then versatility and productivity improve, but the inserts are relegated to negative axial rake angles limiting their capability
Solution Approach 1:
The patent creates a universal cutting insert design with multiple cutting edges that can be indexed for repeated use. The positive axial rake angle configuration enables this multi-functional insert to maintain full structural strength and force capacity across all cutting edges, unlike conventional designs that are limited to negative rake angles
Data Source
AI summary
An indexable cutting insert includes a first component with an outer or top surface and side surfaces. A third component is mirror symmetric with respect to the first component about a vertical or y-axis of the cutting insert. A second component is disposed between the first and third components. Multiple cutting edges are defined at an intersection between the side surfaces and the top surface, wherein the cutting edges define a positive axial rake angle. In one embodiment, the first and third components are in the shape of a polygonal with a star appearance, and the second component is in the shape of a square. The first and third components are offset from one another by a first offset angle, while the second component is offset from the first and third components by a second offset angle to allow the cutting insert to be indexable.