Cutting Insert Corner Radius Layout for Core Removal Stability
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Solution Overview
Problem
Conventional cutting inserts for end mills experience high machining loads and excessive fracture at the corner parts during hole-forming machining, particularly when removing residual cores, leading to reduced machining efficiency and tool stability.
Innovation Solution
The cutting insert design features a larger radius of curvature for the third corner part on the tool center side and adjustable chip breakers, enhancing machining resistance and allowing for controlled chip curling, thereby stabilizing the cutting process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the cutting insert is designed with a small radius of curvature at the corner part to reduce machining resistance, then the corner part becomes more prone to fracture under high loads, but if the radius is increased to improve strength, then machining resistance increases
Solution Approach 1:
The patent applies different radius of curvature values to different corner parts of the cutting insert. Specifically, the third corner part (on the tool center side) has a larger radius of curvature than the first corner part (on the tool periphery side). This local differentiation allows the third corner part to have higher strength to withstand high machining loads during core removal, while the first corner part maintains a smaller radius for lower machining resistance during normal cutting operations.
2Adaptability or versatility
If the cutting insert is designed for multifunctional use with double-sided center edge, then economic efficiency is improved and tool stability is enhanced, but the corner parts experience excessive fracture during hole-forming machining
Solution Approach 1:
The patent maintains the multifunctional double-sided design while locally optimizing the corner parts. The third corner part on each end surface is given a larger radius of curvature to prevent fracture during the high-load core removal operation, while preserving the overall indexable and double-sided configuration for economic efficiency and versatility.
Data Source
AI summary
A cutting insert comprises a first end surface and a second end surface that are each formed in a substantially polygonal plate shape and each include a first long side and a second long side, and a first short side and a second short side that are located between the first long side and the second long side, the first end surface and the second end surface facing each other. The first end surface and the second end surface each have: a first cutting edge extending from the first long side to a first corner part that is located between the first long side and the first short side; and a second cutting edge extending from the second long side to a second corner part located between the second long side and the first short side. A radius of curvature R3 of a third corner part located on an opposite side of the first corner part with the first long side interposed therebetween is larger than a radius of curvature R1 of the first corner part.