Milling Insert Cutting Edge Geometry for Corner Strength
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Solution Overview
Problem
Double-sided face milling inserts with negative axial and radial tipping angles experience increased axial cutting forces, chip formation issues, and chip evacuation difficulties, leading to fragile inserts with reduced service life and poor surface finish due to sharp corner transitions and excessive wear on secondary edges.
Innovation Solution
The milling insert features cutting edges with a main edge that declines and then rises, forming an obtuse angle with secondary edges, which are inclined relative to the neutral plane to reduce sharp corners and distribute material thickness evenly, enhancing corner strength and surface finish while maintaining effective clearance angles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If negative axial and radial tipping angles are used to provide clearance between the insert and workpiece surface, then clearance is improved, but axial cutting forces increase and chip evacuation becomes difficult
Solution Approach 1:
The patent changes the geometric parameters of the cutting edges by forming them with specific inclinations relative to the neutral plane. The main edges are inclined at angles α1 and α2, while secondary edges are inclined at angle ε, creating a complex three-dimensional geometry that provides effective clearance without requiring negative tipping angles, thus reducing axial cutting forces while maintaining reliability
Solution Approach 2:
The patent transitions from a two-dimensional clearance solution (negative tipping angles in the axial and radial directions) to a three-dimensional solution by inclining cutting edges in multiple directions relative to the neutral plane. This multi-dimensional geometric configuration achieves clearance through spatial orientation rather than simple angular tipping, resolving the force-clearance contradiction
2Reliability
If negative axial tipping angle is used to provide clearance, then clearance is improved, but chip formation and evacuation become difficult to control
Solution Approach 1:
The patent modifies the geometric parameters of cutting edges by introducing specific inclination angles (α1, α2 for main edges and ε for secondary edges) relative to the neutral plane. This parameter optimization enables proper chip flow paths and evacuation without the negative tipping angles that cause chip formation issues, while maintaining necessary clearance
3Productivity
If sharp corner transitions are formed between main edges and secondary edges, then cutting performance is improved, but corner strength is reduced and service life decreases
Solution Approach 1:
The patent optimizes the geometric parameters at corner transitions by forming main edges with inclinations α1 and α2 and secondary edges with inclination ε relative to the neutral plane. This parameter optimization creates smooth transitions with adequate radius, maintaining cutting performance while significantly improving corner strength and insert service life
Data Source
AI summary
A milling insert, including an upperside, an underside, and a reference plane parallel thereto. A plurality of indexable cutting edges are formed along a peripheral borderline in transitions between at least the upperside and a number of clearance surfaces. Each cutting edge includes a chip-removing main edge and a surface-wiping secondary edge. The main edge, from a first end of the main edge adjacent to the secondary edge, first declines toward the underside of the milling insert and then, from a lowest part, rises toward an opposite second end of the main edge. The secondary edge is inclined at an angle (ε) in relation to the reference plane as viewed perpendicularly to the clearance surface of the secondary edge, such that a first end of the secondary edge connected to the main edge is situated on a lower level than the opposite, second end of the secondary edge.