Double-Sided Milling Insert Geometry to Prevent Chip Clamping
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Solution Overview
Problem
Conventional milling tools for shoulder milling often cause damage to radially mounted cutting inserts and workpieces due to chip clamping between the cutting insert and the workpiece, leading to damage of active and inactive cutting edges and the machined surface.
Innovation Solution
The milling tool design minimizes the protrusion of the inactive lower cutting edge by ensuring it does not exceed 0.5 mm beyond the outer border, creating a small gap to prevent chips from clinging and getting stuck, thereby protecting the cutting insert and workpiece, and optimizing tool life and machining efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the lower cutting edge protrudes beyond the outer border to ensure complete chip removal, then chip removal efficiency is improved, but chip clamping between the cutting insert and workpiece occurs causing damage
Solution Approach 1:
The patent applies parameter changes by precisely controlling the protrusion distance of the lower cutting edge beyond the outer border to be between 0.01 mm and 0.5 mm. This quantitative parameter optimization resolves the contradiction by finding the optimal value that ensures chip removal while preventing chip clamping damage.
2Reliability
If the lower cutting edge is positioned close to the outer border to prevent chip clamping, then damage prevention is improved, but chip removal capability may be reduced
Solution Approach 1:
The patent resolves this contradiction by establishing an optimal parameter range for the lower cutting edge protrusion (0.01 mm to 0.5 mm). This quantitative control ensures that the cutting edge is close enough to prevent chip clamping damage while maintaining sufficient capability for effective chip removal.
3Duration of action of moving object
If double-sided cutting inserts are used to increase the number of cutting edges, then insert service life is improved, but the risk of chip clamping affecting both upper and lower edges increases
Solution Approach 1:
The patent applies local quality by differentiating the positioning of upper and lower cutting edges relative to the outer border. The lower cutting edge is positioned within 0.5 mm of the outer border while the upper cutting edge maintains its conventional position, creating localized protective geometry that prevents chip clamping on the lower edge while preserving the benefits of double-sided inserts.
Data Source
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AI summary
A milling tool (1) comprising a tool body (101) having a central rotation axis (C), including a front end (101) and a rear end (102) between which an envelope surface (103) extends, wherein at least one insert seat having an outer border (106) delimiting the insert seat from the front end and the envelope surface is provided, and at least one double-sided cutting insert having an upper side, a lower side, an upper cutting edge (204) and a lower cutting edge (214) radially mounted in an insert seat with the lower side abutting a bottom contact surface. An active upper cutting edge (204a) is thereby provided. At least a part of the lower cutting edge neighbouring said outer border and located behind the active upper cutting edge in a direction of rotation does not protrude by more than 0.5 mm with respect to the outer border, and a distance between said part of the lower cutting edge and said outer border is smaller than 0.5 mm in the direction of rotation of the tool body.