Indexable Cutting Insert Geometry for End Mill Ramping
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Solution Overview
Problem
Existing double-sided cutting inserts for small diameter end mills have limitations in ramping capability and manufacturing complexity, particularly requiring multi-axial pressing and resulting in higher cutting forces during operations.
Innovation Solution
The cutting insert design features a first minor cutting edge with a steep slope and extended length, a major cutting edge with low average slope, and a unique geometry allowing uni-axial pressing, along with a clearance chamfer surface and positive rake angles to enhance ramping capability and reduce cutting forces, while facilitating easier manufacturing and improved stability in the end mill tool.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the first minor cutting edge is extended to increase ramping capability, then the ramping angle is increased, but the cutting forces increase
Solution Approach 1:
The patent applies different geometric characteristics to different parts of the cutting insert. The first minor cutting edge has a steep slope (15°-45°) and extended length (80%-95% of major cutting edge) specifically for ramping operations, while the major cutting edge has a low average slope (1°-15°) optimized for chip removal. This local differentiation allows each cutting edge to be optimized for its specific function, enabling high ramping capability while maintaining low cutting forces during the majority chip removal machining.
2Manufacturing precision
If multi-axial pressing is used to manufacture double-sided inserts, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent employs asymmetric geometry in the clearance surfaces. The clearance surface for the first minor cutting edge is inclined at a different angle than the clearance surface for the major cutting edge. This asymmetric design, combined with the specific positioning of the first corner edge intersected by the symmetry plane, enables the double-sided insert to be manufactured by simple uni-axial pressing rather than complex multi-axial pressing, thereby reducing device complexity while maintaining manufacturing precision.
Data Source
AI summary
An indexable cutting insert has a first corner edge forming a front tip of a cutting edge portion configured to project furthest in the direction of an axis of rotation of an end mill tool receiving the insert. A major cutting edge is descending to come closer to the lower surface of the insert along its extension away from the first corner edge. The minor cutting edge extends from the first corner edge while descending from a point of the cutting edge portion most distant to the lower surface all the way to an inner corner of the insert and has a length of 80%-95% of the length of the major cutting edge including a second corner edge in a side elevation view of the cutting insert.