Reversible Milling Insert Geometry for Chip Evacuation and Wear Control
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Solution Overview
Problem
Existing square shoulder milling inserts face challenges in chip control, particularly at large and small cutting depths, with raised circumferential cutting edges risking chip entrapment and increased wear due to uneven compaction during pressing and sintering.
Innovation Solution
A reversible cutting insert with a truncated equilateral triangle-shaped circumferential cutting edge, featuring a first cutting edge portion that intersects a support plane, providing improved chip evacuation and reduced cutting forces by sloping away from the median plane, thus preventing chip entrapment and distributing wear effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the circumferential cutting edge is entirely raised in relation to the first flat surface, then chip control is improved, but chips risk being stuck inside the raised cutting edge and evacuation is hindered
Solution Approach 1:
The cutting edge is designed with non-uniform height distribution: the first cutting edge portion intersects the support plane while the second cutting edge portion is raised above it. This local differentiation allows the first portion to provide chip control while the second portion enables chip evacuation, resolving the contradiction between chip control and chip evacuation.
2Object-affected harmful factors
If the first cutting edge portion is entirely above the support plane, then chip control is improved, but pressing and sintering uniformity deteriorates due to uneven compaction
Solution Approach 1:
The first cutting edge portion intersects the support plane while the second cutting edge portion is raised above it. This local differentiation allows the first portion to provide chip control while the second portion enables chip evacuation, resolving the contradiction between chip control and chip evacuation.
3Force
If the first cutting edge portion slopes towards the median plane, then cutting forces are reduced and chip control is improved, but the length of cutting edge available for cutting is reduced
Solution Approach 1:
The cutting edge is designed with different geometries in different regions: the first cutting edge portion slopes towards the median plane to reduce cutting forces and improve chip control, while the second cutting edge portion is raised and can be made longer to compensate for the reduced effective cutting length, thereby resolving the contradiction between cutting force reduction and cutting edge length maintenance.
Data Source
Figure 1~3
Figure 4~5
Figure 6~7
AI summary
The invention relates to a reversible cutting insert (1) for milling, comprising: opposing and identically or substantially identically top and bottom surfaces (2, 3) interconnected by a continuous peripheral side surface (4), with a median plane (P1) located between the top and bottom surfaces (2, 3) and intersecting the side surface (4), and an insert axis (A1) perpendicular to the median plane (P1) about which the cutting insert (1) is indexable, each top and bottom surface (2, 3) is limited by a circumferential cutting edge intersecting the side surface (4), the circumferential cutting edge in a top view having the shape of a truncated equilateral triangle, each circumferential cutting edge comprising three analogous sets of cutting edges exhibiting three-fold rotational symmetry about the insert axis (A1). A first cutting edge portion (6) intersects a first support plane (P2).