Double-Sided Milling Insert With Recessed Clearance for Ramping
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Solution Overview
Problem
Existing indexable double-sided milling cutting inserts lack sufficient ramping capability and stability, particularly in shoulder milling operations, due to limited clearance and clamping issues during radial and tangential movements.
Innovation Solution
The design features a cutting insert with a through-bore for axial clamping, inclined axial support surfaces, and recesses that increase radial clearance, allowing for improved ramping capability and stability by enabling movement parallel to the tool holder's rotational axis, while the inclined axial support surfaces enhance clamping stability and reduce vibration risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the cutting insert uses a conventional design without recesses, then the structure is simpler, but the ramping capability is limited due to insufficient radial clearance
Solution Approach 1:
The minor side surface is segmented into three distinct regions: a first region with a first axial support surface, a second region with a second axial support surface, and a recess region between them. This segmentation creates the necessary radial clearance through the recess while maintaining structural integrity and support functionality through the divided support surfaces.
Solution Approach 2:
The recess is formed by removing material in the radial direction, creating additional clearance space that enables the cutting insert to perform ramping movements parallel to the rotational axis. This dimensional change from a flat surface to a recessed structure provides the necessary freedom of movement without compromising overall stability.
2Reliability
If the cutting insert uses a conventional clamping design, then the manufacturing is simpler, but the stability and vibration resistance are insufficient during shoulder milling operations
Solution Approach 1:
The clamping structure incorporates locally optimized features including inclined axial support surfaces with specific angle ranges (30-60 degrees for first support surface, 30-60 degrees for second support surface), rounded corners with radii of 0.5-2mm, and precisely positioned recesses. These local quality enhancements improve stability and vibration resistance without requiring a complete redesign of the overall clamping system.
3Adaptability or versatility
If the cutting insert has a compact design without recesses, then the manufacturing precision is easier to maintain, but the clearance for radial movement is insufficient
Solution Approach 1:
The recesses are pre-formed during the insert manufacturing process with predetermined dimensions and positions. This preliminary action ensures that the required radial clearance is built into the insert structure from the beginning, eliminating the need for post-manufacturing adjustments and ensuring consistent clearance control across all inserts.
Data Source
Figure 1~2
Figure 3a~4b
Figure 5a~5c
AI summary
An indexable double-sided milling cutting insert (1), the milling cutting insert (1) comprising: - a top surface (2) and a bottom surface (3), - a through-bore (4) coaxial to a first symmetry axis (X) intersecting the top surface (2) and the bottom surface (3), - a median plane (YZ) extending perpendicularly to the first symmetry axis (X) and virtually dividing the cutting insert (1) into two halves, - two major side surfaces (5), - two minor side surfaces (6), - four main cutting edges (7) formed at the respective transitions of the top surface (2) and the bottom surface (3) with the major side surfaces (5), - four secondary cutting edges (8) formed at the respective transitions of the top surface (2) and the bottom surface (3) with the minor side surfaces (6), - two cutting corners (9) on each of the top surface (2) and the bottom surface (3), the cutting corners (9) being formed between the main cutting edges (7) and the secondary cutting edges (8), the cutting corners (9) being arranged diagonally opposite with respect to the symmetry axis (X), - two secondary corners (18) on each of the top surface (2) and the bottom surface (3), - planar axial support surfaces (10) formed on each of the minor side surfaces (6), wherein - in a top view of the cutting insert (1) - an axial support surface (10) confines an interior angle (α) < 90° with that major side surface (5), which is connected to that minor side surface (6) that carries said axial support surface (10), via a cutting corner (9), wherein an inwardly curved recess (14) is formed on the minor side surfaces (6), extending from the top surface (2) to the bottom surface (3).