Indexable Milling Insert Wedge Angle Optimization
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Solution Overview
Problem
Milling tools for crankshafts and camshafts face high cutting forces and load on the drive due to negative geometry inserts, which are difficult to produce and have low cutting edge-holding ability, while positive geometry inserts reduce forces but are complex and have dimensional issues.
Innovation Solution
An indexable insert with a centrically symmetrical cutting edge contour and a wedge angle between 50° and 85°, featuring a concave wedge shape and rounded edges, reduces cutting forces and enhances edge-holding ability, allowing for efficient chip removal and low wear, and is produced with high accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If negative geometry inserts with 90° wedge angle are used, then high cutting edge-holding ability is achieved, but strong cutting forces act on the milling tool drive
Solution Approach 1:
The patent changes the wedge angle parameter from the conventional 90° to a range of 70°-82°, transforming the negative geometry to positive geometry. This parameter change reduces the cutting forces while maintaining adequate edge-holding ability through optimized geometry
2Force
If positive geometry inserts with 70°-82° wedge angle are used, then cutting forces are reduced, but the inserts have low cutting edge-holding ability and high dimensional tolerances
Solution Approach 1:
The patent applies local quality by providing different surface treatments to different parts of the insert. The cutting face receives a coating or surface treatment to enhance friction and chip control, while the mounting surface receives separate treatment to ensure precise positioning and support, thereby improving edge-holding ability locally without compromising the reduced cutting forces from the positive geometry
3Power
If positive geometry inserts are used, then load on milling cutter drive is reduced, but manufacturing complexity increases with uneven sintered bearing surfaces
Solution Approach 1:
The patent optimizes the wedge angle parameter to 70°-82° and provides specific surface treatments to the mounting surfaces to ensure uniform, machined bearing surfaces rather than uneven sintered surfaces. This simplifies manufacturing by eliminating the need for complex post-processing while maintaining the power reduction benefits of positive geometry
Data Source
AI summary
An indexable insert for a milling tool that includes at least one mounting surface having a through bore for fixing the insert to a rotatable tool, a rounded cutting edge defined by at least one cutting face and a lateral surface, and the at least one cutting face being arranged on a lateral side of the insert and extending from a base. The base is angled with respect to the at least one mounting surface. This abstract is not intended to define the invention disclosed in the specification, nor intended to limit the scope of the invention in any way.