Indexable Cutting Insert With Planar Contact Surfaces for Tight Tolerances
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Solution Overview
Problem
Existing indexable cutting inserts for shoulder milling struggle to produce machine parts that meet tight tolerances due to difficulties in achieving precise machining and stable tool connections.
Innovation Solution
The development of an indexable cutting insert with a triangular top and bottom surface, featuring six sets of cutting edges and planar contact surfaces on each side, which are delimited by main cutting edges at both surfaces. This design enhances tool life and allows for precise positioning and stable mounting in an insert seat.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional indexable cutting inserts are used for shoulder milling, then the basic cutting function is provided, but the manufacturing precision and ability to produce machine parts with tight tolerances deteriorates
Solution Approach 1:
The cutting insert is divided into multiple functional zones with distinct cutting edges (main cutting edges for wall surface, minor cutting edges for bottom surface, and cutting corners for shoulder formation). This segmentation allows each zone to perform its specific function optimally, contributing to tight tolerances in shoulder milling operations.
Solution Approach 2:
Different regions of the cutting insert are designed with specific local properties: main cutting edges have geometry optimized for wall surface milling, minor cutting edges for bottom surface milling, and cutting corners with specific radii for precise shoulder formation. This local quality optimization ensures high manufacturing precision across all machining surfaces.
2Duration of action of moving object
If cutting inserts with multiple cutting edges are used to extend tool life, then the duration of action increases, but the stability and firmness of mounting in the insert seat deteriorates without planar contact surfaces
Solution Approach 1:
The invention adds a new dimension to the mounting interface by introducing planar contact surfaces on the circumferential surfaces of the cutting insert. These surfaces provide additional contact area and dimensional stability between the cutting insert and the insert seat, ensuring firm mounting while accommodating multiple cutting edges for extended tool life.
Solution Approach 2:
The cutting insert design integrates multiple functions: six sets of cutting edges for extended tool life through indexing and flipping, and planar contact surfaces for stable mounting. This multi-functionality allows the single insert to provide both prolonged service life and reliable positioning in the insert seat.
Data Source
AI summary
An indexable cutting insert, arranged for being mounted in an insert seat of a tool body of a shoulder milling tool, includes a triangular top surface, a triangular bottom surface, and three circumferential surfaces extending between the top and bottom surface. On each side of the cutting insert an individual one of the three circumferential surfaces extends along an edge of the triangular top surface and along an edge of the triangular bottom surface. The cutting insert includes at each of the top and bottom surfaces three cutting corners, three main cutting edges and three minor cutting edges. Each cutting corner connects a main cutting edge and a minor cutting edge. Each of the cutting corners, each of the main cutting edges and each of the minor cutting edges are provided at an intersection between the top surface or the bottom surface and one of the circumferential surface.