Milling Insert Geometry for Stable Positioning and Low Axial Runout
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Solution Overview
Problem
Existing cutting inserts for square shoulder milling tools face challenges in maintaining exact positioning and stability, particularly due to variations in thickness affecting axial runout and cutting force direction, leading to suboptimal surface quality and increased stress on clamping arrangements.
Innovation Solution
A cutting insert design featuring a unique geometry with radial and axial relief faces and abutment faces, including obtuse angles and curved surfaces, to enhance stability and positioning, allowing for better absorption of cutting forces and reduced stress on clamping arrangements, while maintaining precise axial and radial support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the insert seat is arranged with a negative radial tipping-in angle to provide radial clearance and prevent interference, then the clearance and interference prevention are improved, but the quality of the machined surface deteriorates and stress on the clamping arrangement increases
Solution Approach 1:
The patent changes the geometric parameters of the insert, specifically providing relief faces that extend outside the cutting edges and abutment faces with specific angles (obtuse angles between 91-120 degrees). These parameter changes allow the insert to compensate for the negative radial tipping-in angle of the insert seat, maintaining surface quality while preventing interference.
Solution Approach 2:
The insert design incorporates asymmetric features with relief faces and abutment faces having specific orientations and angles that are not symmetric. The relief faces extend outside the cutting edges with specific angles, creating an asymmetric geometry that compensates for the negative radial tipping-in angle and improves both surface quality and interference prevention.
2Reliability
If the cutting insert is mounted in an insert seat with negative radial tipping-in angle, then the radial clearance is improved, but the positioning accuracy and stability deteriorate
Solution Approach 1:
The insert is designed with relief faces and abutment faces in advance, before mounting, to compensate for the negative radial tipping-in angle. The relief faces extend outside the cutting edges and the abutment faces have specific angles, preparing the insert to maintain positioning accuracy when mounted in the insert seat with negative radial tipping-in angle.
Solution Approach 2:
The patent modifies the geometric parameters of the insert by providing relief faces with specific extensions and abutment faces with obtuse angles (91-120 degrees). These parameter changes enable the insert to maintain positioning accuracy and stability even when mounted in an insert seat with negative radial tipping-in angle, while still providing necessary radial clearance.
3Stability of the object's composition
If the abutment faces are oriented to support the cutting insert in multiple directions, then the support stability is improved, but the complexity of the insert geometry increases
Solution Approach 1:
The relief faces and abutment faces of the insert are designed to serve multiple functions simultaneously. The relief faces extend outside the cutting edges to provide relief while also contributing to radial support. The abutment faces with specific angles provide both axial and radial support, reducing the need for separate dedicated support surfaces and simplifying the overall geometry while maintaining multi-directional support stability.
Solution Approach 2:
The patent merges the functions of relief faces and support surfaces by designing relief faces that extend outside the cutting edges and also provide radial support. The abutment faces are designed with obtuse angles that simultaneously provide axial and radial support functions, combining multiple support functions into unified geometric features, thereby reducing complexity while maintaining stability.
Data Source
AI summary
A cutting insert includes a first and a second pair of opposing side surfaces. As seen towards a first side surface, a first axial relief face and a first axial abutment face form part of a first surface grouping on a first side of a longitudinal plane. As seen towards a second side surface, a second axial relief face and a second axial abutment face form part of a second surface grouping on the first side of the longitudinal plane. The first axial abutment face forms a substantially flat surface and extends perpendicularly to a median plane of the insert. The second axial abutment face forms a substantially flat surface and extends perpendicularly to the median plane. A second side surface of the first pair of opposing side surfaces has a first and a second radial abutment face.