Double-Sided Milling Insert for 90-Degree Corner Machining
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Solution Overview
Problem
Existing milling inserts for machining 90° corners in metallic workpieces are expensive and suffer from unstable localization, which affects their performance.
Innovation Solution
A double-sided milling insert with a trigon-shaped or hexagonal design made of directly pressed hard metal, featuring major and minor cutting edges with specific geometric configurations and coatings, designed for rigid mounting in a milling body to enhance cutting efficiency and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional milling inserts are used for milling 90° corners, then cutting function is provided, but localization is unstable and cost is high
Solution Approach 1:
The milling insert employs asymmetric geometry with distinct major cutting edges for primary material removal and minor cutting edges for finishing and chip groove formation. The insert body has an asymmetric shape with a first side containing major cutting edges and a second side containing minor cutting edges, enabling stable localization through the asymmetric support surfaces that mate with corresponding pockets in the milling tool body.
Solution Approach 2:
The cutting insert is segmented into functionally distinct zones: major cutting edges for aggressive material removal, minor cutting edges for chip groove formation and surface finishing, and separate support surfaces for localization. This segmentation allows each zone to be optimized for its specific function while maintaining overall structural integrity and stable mounting.
2Productivity
If complex geometric configurations are added to improve cutting performance, then chip discharge and cutting efficiency improve, but manufacturing complexity and cost increase
Solution Approach 1:
The invention merges multiple cutting functions into a single integrated insert body. The major cutting edges and minor cutting edges are formed as continuous geometric features on the same insert, eliminating the need for separate tools or multiple machining operations. The chip groove is integrated into the insert geometry itself, formed by the minor cutting edges, combining chip evacuation functionality with the cutting structure.
Solution Approach 2:
The insert utilizes specific geometric parameters including the angle relationships between major and minor cutting edges, the positioning of support surfaces relative to cutting edges, and the configuration of chip grooves. These parameter optimizations enable efficient chip discharge and effective cutting performance while maintaining manufacturability through direct pressing of hard metal with standardized tolerances.
3Object-generated harmful factors
If minor cutting edges are added along beveled corners to improve chip discharge, then chip removal ability improves, but insert complexity and cost increase
Solution Approach 1:
Instead of adding complex chip evacuation systems to conventional inserts, the invention inverts the approach by using the minor cutting edges themselves to form the chip groove through their geometric configuration. The minor cutting edges are positioned and angled to naturally create chip discharge pathways, eliminating the need for separate chip evacuation mechanisms and reducing overall insert complexity.
Data Source
Figure 1A~1E
Figure 1F~1B
Figure 1D~1C
AI summary
The present invention relates to an indexable milling insert and a milling tool for chip removing machining. The milling insert is intended to be able to mill substantially perpendicular corners in a work piece. The milling insert (10) comprises an upper side (11 ), a lower side (12) and edge surfaces (13A,13B,14A,14B,15A,15B) extending there between. The upper side (11 ) and the lower side (12) are substantially identical. An imaginary circle (C) inscribed in the milling insert (10) touches the milling insert periphery in four to six points (S1 ,S2). Lines of intersection between the edge surfaces and the sides form relative to each other substantially perpendicular main cutting edges (16) and minor cutting edges (17). Each of the side (11 ,12) includes a support surface (18,19), each of which being provided in a plane (P1 ,P2). Each minor cutting edge (17) projects from the plane (P1 ,P2) of the associated support surface (18,19). Each major cutting edge (16) intersects the plane (P1 ,P2) of the associated support surface.