Indexable Cutting Insert Layout for Stable Grooving in Tight Spaces

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Solution Overview

Problem

Existing cutting tools for grooving operations in limited spaces lack stability and efficient manufacturing, particularly when accessing rotating workpieces, due to inadequate design and material usage.

Innovation Solution

An indexable cutting insert with a central mounting portion and two cutting portions located in diagonally opposite quadrants, featuring diverging abutment surfaces and rake surfaces, is designed for improved stability and efficient manufacturing, allowing for high-stability retention in insert holders with reduced complexity and cost.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If cutting inserts have two cutting portions located in diagonally opposite quadrants for grooving operations in limited spaces, then accessibility and versatility are improved, but stability and retention in insert holders deteriorate

Engineering Contradiction:

Improveversatility for grooving operationsVSAvoidstability in insert holder

Core Design Contradiction:

Adaptability or versatilityVSStability of the object's composition

Solution Approach 1:

The cutting insert is segmented into two separate cutting portions located in diagonally opposite quadrants, each capable of independent grooving operations. This segmentation allows the insert to perform multiple grooving operations with different insert orientations, improving versatility while maintaining stability through proper positioning of each cutting portion.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The cutting insert employs asymmetric positioning of cutting portions in diagonally opposite quadrants rather than symmetric placement. This asymmetric arrangement optimizes accessibility to rotating workpieces in limited spaces while maintaining stable retention through carefully designed abutment element positions that compensate for the asymmetric cutting portion locations.

Inventive Principle:

Principle #4Asymmetry

2Stability of the object's composition

If cutting inserts use complex abutment surfaces for stable retention, then stability is improved, but manufacturing complexity and cost increase

Engineering Contradiction:

Improvestability in insert holderVSAvoidmanufacturing complexity

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The abutment elements are designed with localized diverging abutment surfaces that provide stable retention only in the critical contact regions with the insert holder. Rather than making the entire insert surface complex, the local quality principle applies simplified geometry elsewhere, reducing manufacturing complexity while maintaining stability where needed.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The abutment elements use simple geometric parameters (diverging surfaces with specific angles) that are easy to manufacture yet provide adequate stability. By optimizing the divergence angle and positioning parameters, the design achieves stable retention without requiring complex surface geometries, thereby reducing manufacturing complexity and cost.

Inventive Principle:

Principle #35Parameter changes

3Stability of the object's composition

If cutting inserts are designed for high stability with multiple support points, then stability is improved, but manufacturing cost and complexity increase

Engineering Contradiction:

Improvestability in insert holderVSAvoidmanufacturing efficiency

Core Design Contradiction:

Stability of the object's compositionVSEase of manufacture

Solution Approach 1:

The design extracts only the essential stability-providing features (two diverging abutment surfaces per abutment element) rather than implementing multiple complex support points. This extraction approach maintains adequate stability for diagonal quadrant cutting portions while simplifying manufacturing by eliminating unnecessary support structures.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Instead of designing multiple support points radiating from the center, the invention inverts the approach by using two abutment elements positioned to provide stability through their diverging surfaces. This inverted design achieves stability with fewer elements, improving ease of manufacture while maintaining performance.

Inventive Principle:

Principle #13The other way round (Inversion)

Data Source

PatentUS11484948B2Indexable cutting insert having two cutting portions located in diagonally opposite quadrants and two lower abutment elements, and cutting tool therefor

Publication Date: 2022.11.01 ISCAR LTD

AI summary

An indexable cutting insert has a central mounting portion and two cutting portions. The central mounting portion has opposing upper and lower surfaces. The lower surface has two abutment elements associated therewith, each abutment element having two diverging abutment surfaces forming two abutment angles. The two cutting portions extend away from the central mounting portion, have distal cutting edges, and are entirely located in diagonally opposite imaginary quadrants of four quadrants defined by two mutually perpendicular quadrant planes. Two abutment bisector planes bisecting the two abutment angles and one of the quadrant planes are parallel or coincident. In a top view, the two cutting portions extend away from the central mounting portion in opposite directions. Two cutting bisector lines parallel to the two directions and bisecting the two cutting edges are mutually offset. A cutting tool has an insert holder and the cutting insert removably retained therein.