Milling Insert Rear Protuberance for Axial Force Support
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Solution Overview
Problem
Existing cutting inserts for milling cutters face limitations such as restricted insert capacity, limited maneuverability due to quarter-circle cutting edge geometry, and suboptimal absorption of axial forces during drilling operations, particularly when drilling in downward or upward motions.
Innovation Solution
A cutting insert design featuring a peripheral surface with a 120° arcuate cutting edge, multifaceted rear surface, and eccentric through hole, allowing for increased maneuverability and improved axial force absorption, with a retaining screw system that secures the insert in a pocket with multiple abutment regions for enhanced stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a cutting insert with quarter-circle cutting edge geometry is used, then the insert can be mounted in limited positions, but the maneuverability of the cutting tool is limited
Solution Approach 1:
The cutting insert employs asymmetric geometry with a 120° arcuate cutting edge instead of the conventional quarter-circle (90°) shape. This asymmetric design enables the insert to perform cutting operations in multiple directions including downward drilling, upward drilling, and lateral milling, thereby significantly improving tool maneuverability and versatility without compromising ease of operation
2Ease of manufacture
If abutment surfaces are not perpendicular to drilling direction, then mounting is simplified, but axial forces are not optimally absorbed
Solution Approach 1:
The cutting insert features a specialized abutment surface configuration where specific surfaces are oriented perpendicular to the drilling direction to optimally absorb axial forces during downward or upward drilling operations. This local optimization of surface orientation maintains ease of mounting while significantly improving the insert's ability to withstand axial cutting forces
3Device complexity
If only two cutting inserts can be attached to the cutting tool, then the tool structure is simple, but insert replacement frequency increases
Solution Approach 1:
The cutting tool is designed with multiple insert pockets (more than two) that can accommodate the universal cutting insert. This multi-functional tool holder configuration allows simultaneous installation of multiple inserts, enabling continuous cutting operations with reduced replacement frequency while maintaining reasonable structural complexity through standardized pocket design
Data Source
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AI summary
A cutting insert (24) for mounting in a socket on an insert holder (22) of a milling cutter (20). The cutting insert has opposing top and bottom surfaces and a peripheral surface extending therebetween, forming one or two cutting edges. The peripheral surface has a front arcuate surface and a rear surface. The rear surface has a protuberance that extends in a direction away from a central region of the front surface. The protuberance is located in the socket. The socket includes a first socket side abutment surface for providing primarily axial support for the cutting insert against cutting forces acting in an axial rearward direction during a milling operation.