Cutting Insert Protrusion Structure for Stable Pocket Coupling
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Solution Overview
Problem
Existing cutting inserts face challenges in maintaining stable coupling with cutting tools, leading to inconsistent clamping forces and reduced efficiency during cutting processes.
Innovation Solution
A cutting insert design featuring a hexahedral shape with inclined surfaces, through-holes, and protrusions that increase contact area with the insert pocket, enhancing clamping force and stability through rotational symmetry and specific edge configurations for improved rigidity and chip discharge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional cutting insert design is used, then the structure is simple, but the contact area with the insert pocket is insufficient leading to unstable coupling
Solution Approach 1:
The top surface of the cutting insert is segmented into multiple protrusions (first, second, third protrusions) that contact different regions of the insert pocket. This segmentation increases the contact area and distributes the clamping force across multiple points, improving coupling stability without requiring a fundamentally complex structure
Solution Approach 2:
The invention transitions from a conventional flat top surface to a three-dimensional surface with multiple protrusions at different heights and positions. This dimensional change allows the insert to contact the insert pocket at multiple levels, significantly increasing the contact area and enhancing coupling reliability
2Force
If the contact area between cutting insert and insert pocket is increased, then clamping force and stability are improved, but the manufacturing complexity increases
Solution Approach 1:
The clamping force is distributed across multiple protrusions rather than concentrated at a single point. Each protrusion contacts a specific region of the insert pocket, allowing the total clamping force to be divided into multiple smaller force vectors that collectively secure the insert more effectively
Solution Approach 2:
Different protrusions are positioned to contact specific local regions of the insert pocket that may have varying structural properties. This local quality approach ensures that each protrusion engages with the most suitable portion of the pocket for optimal force transmission and clamping effectiveness
3Stability of the object's composition
If protrusions are added to increase contact area, then coupling stability improves, but the device complexity increases
Solution Approach 1:
The top surface is divided into multiple discrete protrusions rather than a continuous complex structure. This segmentation achieves stability through distributed contact points while keeping each individual protrusion geometrically simple and easy to manufacture
Solution Approach 2:
The invention uses a moderate number of protrusions (three main protrusions) rather than an excessive number. This partial action approach provides sufficient contact area and coupling stability without over-complicating the geometry, maintaining a balance between stability and simplicity
Data Source
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AI summary
A cutting insert includes a top surface, a bottom surface, a pair of sub-side surfaces and a pair of main side surfaces configured to connect ends of the top surface and the bottom surface in a width direction and a longitudinal direction to each other respectively, a plurality of corner side surfaces configured to connect the pair of sub-side surfaces to the pair of main side surfaces, a through-hole configured to pass through central portions of the top surface and the bottom surface, and a cutting part disposed on at least a portion of portions at which the top surface and the bottom surface intersect the pair of sub-side surfaces, the pair of main side surfaces, and the plurality of corner side surfaces. The top surface may include a mounting surface in which the through-hole is defined and a pair of protrusions convexly protruding upward from the mounting surface.