Milling Insert Geometry for Combined Roughing and Finishing
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Solution Overview
Problem
Existing cutting inserts for milling tools face challenges in achieving a balance between long service life, high metal removal rates, and good surface quality, often requiring complex designs and multiple machining steps, which increases production costs and complexity.
Innovation Solution
A cutting insert design with continuous lateral surfaces, where finishing cutting edges have an enlarged incircle and roughing cutting edges have a reduced incircle, providing stability and ease of production, and featuring inclined, convex, or concave cutting edges to optimize cutting behavior and engagement with the workpiece, allowing for mixed placement with conventional inserts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If cutting inserts are designed with complex geometries to achieve both roughing and finishing capabilities, then functionality is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The cutting insert employs different incircle diameters for different cutting edges: finishing cutting edges have an enlarged incircle diameter while roughing cutting edges have a reduced incircle diameter. This local differentiation allows each cutting edge to be optimized for its specific function without requiring complex overall geometry, resolving the contradiction between versatility and manufacturing simplicity.
2Manufacturing precision
If cutting edges are designed to be highly precise for good surface quality, then machining precision is improved, but service life decreases due to increased brittleness
Solution Approach 1:
The patent applies different incircle diameter adjustments to different cutting edges based on their function. Finishing cutting edges use enlarged incircle diameters for precision and surface quality, while roughing cutting edges use reduced incircle diameters for durability and impact resistance. This localized optimization allows each edge to balance precision and service life according to its specific operational requirements.
3Manufacturing precision
If multiple machining steps are used to achieve both roughing and finishing, then machining quality is improved, but production time increases
Solution Approach 1:
The cutting insert combines both roughing and finishing cutting edges on a single tool, allowing both operations to be performed in one machining step. The different incircle diameter configurations enable each edge type to perform its designated function effectively, merging multiple machining steps into one operation and thereby reducing production time while maintaining machining quality.
4Duration of action of moving object
If cutting inserts are designed for long service life with simplified geometry, then durability is improved, but cutting precision and surface quality deteriorate
Solution Approach 1:
The patent implements local quality differentiation by assigning enlarged incircle diameters to finishing cutting edges for precision and surface quality, while roughing cutting edges use reduced incircle diameters for durability. This localized optimization ensures that precision requirements are met where needed without compromising overall service life, as each cutting edge is tailored to its specific functional requirements.
Data Source
AI summary
The invention relates to a cutting insert having a polygonal upper side. Cutting edges, which are alternately configured as roughing cutting edges and finishing cutting edges, are provided at the edges of the upper side. The finishing cutting edges define an incircle (K1) having a diameter that is enlarged in comparison to a nominal size of the cutting insert, and the roughing cutting edges define an incircle (K2) having a diameter that is reduced in comparison to the nominal size of the cutting insert. The invention further relates to a cutting tool having a tool body on which at least one such cutting insert is disposed.