Milling Insert with Flat Corner Edge for Burr Suppression
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Solution Overview
Problem
Existing face milling processes form burrs at corner portions of machined surfaces, requiring separate deburring tools, leading to reduced productivity, increased costs, and inefficient utilization of cutting inserts.
Innovation Solution
A milling cutting insert with intersecting cutting edges, including a major cutting edge, a flat cutting edge, and a minor cutting edge inclined at 10° to 30°, featuring different surface roughness on side faces to prevent chip feeding and suppress burr formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a separate deburring tool with a circular cutting insert is used to remove burrs, then burr removal is achieved, but productivity decreases and tool cost increases due to requiring multiple cutting inserts
Solution Approach 1:
The patent combines the major cutting function and deburring function into a single cutting insert. The insert includes both a major cutting edge for primary material removal and a flat cutting edge at the corner portion for deburring, eliminating the need for separate deburring tools and multiple cutting inserts.
Solution Approach 2:
The cutting insert is designed to perform multiple functions simultaneously: it acts as both a major cutting insert for material removal and a deburring insert for corner portion burr removal. This multi-functionality allows one insert to replace what previously required two separate inserts.
2Object-affected harmful factors
If two kinds of cutting inserts (major cutting insert and deburring-exclusive cutting insert) are used, then both cutting and deburring functions are fulfilled, but tool inventory control becomes complex and cost increases
Solution Approach 1:
The patent merges the functionality of two separate cutting inserts into one unified insert design. The single insert contains both the major cutting edge and the flat cutting edge, simplifying tool inventory management by requiring only one type of insert instead of two different types.
3Object-affected harmful factors
If a combination of major cutting insert and deburring-exclusive cutting insert is used, then both functions are performed, but utilization efficiency decreases because the other insert must be replaced when one reaches its life limit
Solution Approach 1:
By combining both cutting and deburring edges in a single insert, the patent ensures that when the insert reaches its life limit, both functions are simultaneously replaced. This eliminates the waste of replacing one insert while the other still has remaining life, maximizing utilization efficiency.
Data Source
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Figure 5
AI summary
To reduce burrs that may be formed at a corner portion of a machined surface in a face milling process, there is provided a cutting insert that does not tend to form burrs. A milling cutting insert includes cutting edges 5 provided as ridges each defined by an upper or lower face 2 or 4 and a side face 3 that intersect each other, the cutting edges including a flat cutting edge 5b. The cutting edges 5 include a major cutting edge 5a provided between adjacent ones of corner portions, the flat cutting edge 5b provided at the corner portion, and a minor cutting edge 5c provided between the major cutting edge and the flat cutting edge. A surface roughness of a side face 3a that is continuous with the major cutting edge 5a is higher than a surface roughness of a side face 3c that is continuous with the minor cutting edge 5c.