Milling Insert Plateau Geometry for Chip Evacuation Across Tool Diameters
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Solution Overview
Problem
Cutting inserts with a major portion of the main cutting edge projecting above the central surface are suitable for small tool diameters but fail to provide adequate chip formation properties for larger diameters, leading to issues with chip evacuation and reduced tool life when used in milling tools with larger cutting diameters.
Innovation Solution
A cutting insert design featuring a positively inclined main cutting edge with a plateau extending along its projecting portion, which compensates for varying distances and enhances chip formation, allowing for consistent chip diameter and improved evacuation across a range of tool diameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If a major portion of the main cutting edge projects above the central surface, then cutting action and tool life are improved for small tool diameters, but chip formation properties deteriorate for large tool diameters
Solution Approach 1:
The cutting insert employs different surface geometries at different locations: the rake surface provides a large rake angle for light cutting and good chip formation, while the plateau provides a smaller effective rake angle for better chip formation in large diameter tools. This local differentiation allows the same insert to perform optimally across a wide range of tool diameters.
Solution Approach 2:
The invention introduces a plateau that extends in the radial direction from the central surface, creating a stepped geometry that effectively adds a dimensional element to the cutting edge structure. This plateau modifies the chip flow path and effective rake angle without changing the basic insert geometry, enabling adaptation to different tool diameters.
2Force
If a major portion of the main cutting edge projects above the central surface, then cutting action is improved, but arc of engagement increases for large tool diameters
Solution Approach 1:
The plateau creates a localized modification to the cutting edge geometry that affects how the insert engages with the workpiece. By providing a stepped surface structure, the effective engagement length is modified locally at the cutting zone, allowing better performance in large diameter tools where arc of engagement is inherently larger.
3Reliability
If different cutting inserts are used for small and large tool diameters, then optimal performance is achieved for each diameter range, but device complexity increases
Solution Approach 1:
The cutting insert is designed with a multi-functional geometry that allows it to perform optimally across different tool diameter ranges. The combination of rake surface and plateau enables the same insert to provide light cutting action for small diameter tools while maintaining adequate chip formation for large diameter tools, eliminating the need for multiple specialized inserts.
Solution Approach 2:
The invention effectively changes the geometric parameters of the cutting insert by introducing the plateau structure. This modifies the effective rake angle and chip flow characteristics, allowing the insert to adapt its performance characteristics based on the tool diameter without requiring physically different inserts.
Data Source
AI summary
A cutting insert for a milling tool including an upper side having a central surface, a lower side, a peripheral side surface, and a cutting edge formed between the upper side and the peripheral side surface. The cutting edge having a positively inclined main cutting edge projecting at least partly above the central surface. The upper side includes a rake surface extending inside of and along the at least one cutting edge, sloping downward toward the central surface. A plateau, elevated with respect to the central surface and extending along the main cutting edge, is formed inside the rake surface. A transition between the rake surface and the plateau extends at an angle ϕ2 with respect to an upper extension plane, wherein ϕ2>0°.