Milling Cutting Insert with Curved Edge Profile
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Solution Overview
Problem
Conventional milling cutters with square or triangular cutting inserts are limited in cutting depth and require high power consumption when machining 90° shoulders due to the restricted size of main lips and the design of cutting edges and corners.
Innovation Solution
A cutting insert with a square or triangular rake face featuring linear cutting edges and curved corners, where each cutting edge has a sloping region extending beyond the tangential point and rising to a maximum before sloping downward, allowing for greater cutting depths and enabling all edges to function as both main and facing lips, resulting in a rotationally symmetrical form with increased edge usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If conventional cutting inserts with restricted main lip size are used, then the device complexity is reduced, but the cutting depth is limited
Solution Approach 1:
The cutting edge is designed with a curved profile featuring a rising region that extends beyond the tangential point and culminates in a cutting edge maximum. This curvature allows the main lip to extend further axially, increasing cutting depth capability while maintaining structural integrity of the insert
Solution Approach 2:
The cutting edge profile incorporates a third dimension by extending the main lip axially beyond the traditional planar cutting edge. The rising region and cutting edge maximum create an elevated portion that projects further from the rake face, enabling greater cutting depth without increasing the insert's lateral footprint
2Productivity
If conventional cutting edges with limited facing lip functionality are used, then the manufacturing precision is maintained, but the productivity is reduced
Solution Approach 1:
Each cutting edge on the insert is designed with both main lip and facing lip functionality. The rising region and cutting edge maximum enable the same edge to perform both roughing (main lip) and finishing (facing lip) operations, allowing all four cutting edges to be fully utilized for 90° shoulder machining without requiring separate dedicated edges
3Length of moving object
If milling cutters with conventional cutting inserts are used, then the power consumption is reduced, but the cutting depth is limited
Solution Approach 1:
The curved cutting edge profile with its rising region and cutting edge maximum creates an optimized chip flow path. This geometry reduces cutting resistance and power consumption by distributing the cutting load more evenly along the extended main lip, enabling deeper cuts without proportional increases in power demand
4Length of moving object
If cutting edges with extended rising regions are used, then the cutting depth is increased, but the ease of manufacture is reduced
Solution Approach 1:
The rising region and cutting edge maximum are formed as smooth curved transitions rather than sharp angles or complex multi-surface geometries. This curvature can be efficiently produced through conventional grinding or CNC machining processes, maintaining manufacturing feasibility while achieving the extended cutting depth
Data Source
AI summary
The invention relates to a milling cutting insert having a square or triangular shaped cutting face delimited in the plan view by a peripheral cutting edge having linear cutting edges (10) and curved cutting corners (11). According to the invention, each of the cutting edges (10) comprises an inclined region (10a) sloping toward a cutting corner (11), extending beyond the tangential point (14) determined by the point at which the linear cutting edge (10) transitions into a curved cutting corner (11), wherein adjacent thereto the cutting edge (10b) rises prior to the point (24) determined by a cutting corner angle bisector (15), wherein said rising region (10b) extends to a cutting edge maximum (17) on the other side of the cutting corner (11) on the adjacent cutting edge (10), which is linear in plan view, from where the cutting edge (10) continues, again inclined and sloping downward, resulting in a rotationally symmetric form having identically shaped cutting edges.