Indexable Cutting Insert Geometry for Precise Shoulder Milling
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Solution Overview
Problem
Existing indexable cutting inserts for shoulder milling struggle to produce machine parts with tight tolerances due to difficulties in achieving precise and stable mounting.
Innovation Solution
The design of an indexable cutting insert with a triangular top and bottom surface, featuring six sets of cutting edges and planar contact surfaces that extend along the main cutting edges, providing enhanced precision and stability by allowing firm seating in the tool body and minimizing vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional cutting inserts are used, then the structure is simple, but the mounting precision and stability are insufficient
Solution Approach 1:
The cutting insert is divided into distinct functional surfaces: planar contact surfaces for mounting, inclined surfaces for chip flow, and cutting edges for material removal. This segmentation allows each surface to be optimized independently for its specific function, improving overall mounting precision while maintaining manageable structural complexity.
Solution Approach 2:
The invention transitions from conventional flat contact surfaces to three-dimensional planar contact surfaces with specific inclinations and orientations. By utilizing multiple dimensions and angles, the insert achieves superior mounting precision and stability without simply increasing overall complexity.
2Stability of the object's composition
If conventional cutting inserts are used, then the design is simple, but vibrations occur during milling
Solution Approach 1:
Different regions of the cutting insert are given different geometric properties: planar contact surfaces for stability, inclined surfaces for chip evacuation, and specific edge geometries for cutting performance. This local differentiation enhances overall insert stability during milling operations.
Solution Approach 2:
The cutting insert combines multiple geometric features and surface types into a single integrated component, creating a composite structure that leverages the advantages of each element to reduce vibrations and improve stability during operation.
3Duration of action of moving object
If cutting edges are provided only on one surface, then the insert structure is simple, but the tool life is limited
Solution Approach 1:
The cutting insert is designed with cutting edges on both top and bottom surfaces, allowing it to perform cutting operations in multiple directions and orientations. This multi-functionality extends tool life by enabling indexable reuse of multiple cutting edges without requiring additional inserts.
Solution Approach 2:
The insert is designed for periodic indexing, where used cutting edges are rotated out of position and fresh cutting edges are brought into operation. This periodic action of indexing and flipping maximizes the utilization of all cutting edges throughout the insert's service life.
Data Source
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AI summary
The present invention relates to an indexable cutting insert (4) for mounting in an insert seat (3) of a tool body (2) of a shoulder milling tool (1) , the cutting insert (4) being generally defined by a triangular top surface (5), a triangular bottom surface (6), and three circumferential surfaces (7) extending between the top surface (5) and the bottom surface (6), wherein on each side of the cutting insert (4) an individual one of the three circumferential surfaces extends along an edge of the triangular top surface (5) and along an edge of the triangular bottom surface (6), the cutting insert (4) comprising at each of the top surface (5) and the bottom surface (6) three cutting corners (8), three main cutting edges (9) and three minor cutting edges (10), wherein each cutting corner (8) connects a main cutting edge (9) and a minor cutting edge (10), wherein each of the cutting corners (8), each of the main cutting edges (9) and each of the minor cutting edges (10) are provided at an intersection between the top surface (5) or the bottom surface (6) and one of the circumferential surfaces (7), and wherein each of the circumferential surfaces (7) comprises a planar contact surface (15), which planar contact surface is delimited by a main cutting edge (9) at the top surface (5) and by a main cutting edge (9) at the bottom surface (6).