Milling Insert Abutment Geometry for Dual-Angle Cutting Positions
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Solution Overview
Problem
Existing milling cutting inserts lack versatility in accommodating both large cutting depths for traditional milling and small cutting depths for high feed milling operations without requiring multiple tool holders or indexing positions.
Innovation Solution
A milling cutting insert with discrete planar abutment surfaces inclined at an outer angle of 190° to 220°, allowing it to be securely positioned in a tool holder at two distinct angular positions for each indexing position, enabling use in both traditional milling and high feed milling operations by rotating the insert between these positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a milling cutting insert is designed with a single angular position, then the tool holder structure is simple, but the insert cannot accommodate both traditional milling and high feed milling operations
Solution Approach 1:
The cutting insert is designed with two distinct angular positions that allow it to perform both traditional milling and high feed milling operations. The first angular position (0° to 10°) is optimized for traditional milling with larger cutting depths, while the second angular position (15° to 40°) is optimized for high feed milling with smaller cutting depths. This multi-functionality enables a single insert design to replace what would traditionally require multiple specialized inserts or tool holders.
Solution Approach 2:
The cutting insert incorporates a rotatable design that allows dynamic adjustment between two fixed angular positions. The insert can be rotated within the tool holder to switch between the first angular position (0° to 10° relative to the radial direction) and the second angular position (15° to 40° relative to the radial direction). This dynamic repositioning capability enables the same insert to adapt to different machining requirements without changing the tool holder or insert design.
2Adaptability or versatility
If multiple tool holders are used to accommodate different cutting depths, then the adaptability to different milling operations is improved, but the device complexity and tooling requirements increase
Solution Approach 1:
The tool holder is designed with a universal structure that can accommodate the cutting insert in two different angular positions. Rather than requiring separate tool holders for traditional milling and high feed milling, this single tool holder design incorporates features that allow the insert to be positioned at either the first angular position (0° to 10°) or the second angular position (15° to 40°), making the tool holder itself multi-functional.
Solution Approach 2:
The invention merges the functionality of multiple specialized tool holders into a single universal tool holder design. By integrating features that support both angular positions within one tool holder structure, the design eliminates the need for multiple separate tool holders, thereby reducing tooling complexity while maintaining adaptability to different milling operations.
3Productivity
If the cutting insert is designed with fixed angular position, then the manufacturing precision is easier to control, but the material utilization and insert life are reduced
Solution Approach 1:
The cutting insert incorporates a rotatable design that allows dynamic adjustment between two fixed angular positions. The insert can be rotated within the tool holder to switch between the first angular position (0° to 10° relative to the radial direction) and the second angular position (15° to 40° relative to the radial direction). This dynamic repositioning capability enables the same insert to adapt to different machining requirements without changing the tool holder or insert design.
Solution Approach 2:
The cutting insert design segments the angular positioning into two distinct, pre-defined positions rather than requiring continuous adjustment. The first position (0° to 10°) and second position (15° to 40°) are clearly defined angular ranges that can be manufactured with standard precision. This segmentation approach simplifies manufacturing while still providing the flexibility to optimize for different milling operations, thereby improving material utilization without excessively complicating the manufacturing process.
Data Source
Figure 1~2
Figure 3a~3b
Figure 4a~4b
AI summary
A milling cutting insert (1) having a substantially triangular shape, the cutting insert (1) comprising: a top side (2) an underside (3) circumferential side surfaces (4) extending between the top side (2) and the underside (3), cutting edges (5) being formed at the transition of the circumferential side surfaces (4) to the top side (2) and / or the underside (3), wherein on circumferential side surfaces (4) at least two discrete planar abutment surfaces (61, 62) are formed for positioning the cutting insert (1) in a tool holder (8), wherein the at least two discrete planar abutment surfaces (61, 62) are inclined with respect to each other at an outer angle of between 190° and 220° and wherein the abutment surfaces (61, 62) are spaced from each other with respect to the circumferential direction of the cutting insert (1).