Milling Insert Geometry for Stable Sintering Accuracy
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Solution Overview
Problem
Cutting inserts manufactured using multiaxial pressing (MAP) often distort during sintering, leading to shape errors that require complex tool design and subsequent grinding corrections, which complicates the manufacturing process and increases the risk of burrs and dimensional inaccuracies.
Innovation Solution
A cutting insert design with a specific geometry that allows for improved form stability during sintering, featuring a circumferential surface formed by two side parts of the MAP pressing tool that meet along a longitudinal plane, reducing the need for recesses and simplifying the manufacturing process, thereby minimizing burrs and achieving better tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a first recess is formed in the insert body during the MAP operation, then the cutting insert can be formed with complex geometry, but the insert distorts during subsequent sintering, leading to shape errors
Solution Approach 1:
The pressing tool is divided into two separate side parts that press from opposite directions. This segmentation allows each side part to form surfaces without creating recesses that would cause distortion, while still achieving complex insert geometry through the coordinated action of both side parts.
Solution Approach 2:
Instead of forming recesses in the insert body during pressing (which causes distortion), the invention inverts the approach by having the two side parts of the pressing tool form the surfaces directly. The side parts are designed to clear the green body after pressing, eliminating the need for recesses and preventing distortion during sintering.
2Adaptability or versatility
If recesses are formed during MAP operation to achieve complex shapes, then the cutting insert geometry can be varied, but the insert body distorts during sintering requiring grinding corrections
Solution Approach 1:
The pressing tool is segmented into two independent side parts that can be designed and manufactured separately. Each side part forms specific surfaces of the insert, and their coordinated movement achieves complex geometry without requiring recesses, thereby reducing pressing tool complexity while maintaining insert geometry versatility.
Solution Approach 2:
The invention moves from a single pressing direction with recesses to a dual-side pressing approach. By adding the dimension of bilateral pressing with coordinated side parts, the system achieves complex insert geometry without the harmful effect of recesses, reducing both tool complexity and post-processing requirements.
3Ease of manufacture
If conventional pressing is used instead of MAP, then the green body is easier to form, but complex shapes cannot be achieved
Solution Approach 1:
The pressing operation is segmented into multiple independent pressing actions from different directions. The two side parts of the MAP tool press sequentially or simultaneously from opposite sides, enabling complex three-dimensional geometry to be formed while maintaining the simplicity and ease of conventional pressing operations for each individual pressing action.
Solution Approach 2:
The MAP pressing tool employs dynamic, coordinated movement of its two side parts. The side parts can move independently and are designed to clear the green body after pressing, allowing the formation of complex shapes through dynamic pressing sequences while maintaining ease of manufacture through standardized pressing mechanisms.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design enables the production of cutting inserts with improved form stability during sintering, reducing the complexity of tool manufacturing, minimizing burrs, and achieving precise dimensional accuracy without the need for post-sintering grinding corrections.
Implementation Method 1
The green body as such is porous. When sintered, the green body is compacted, shrinks in size and forms the cutting insert.
Data Source
AI summary
A cutting insert for a milling tool is provided. A longitudinal plane extends halfway between a first pair of opposing side surfaces of the cutting insert. A first axial relief face adjacent to the a auxiliary cutting edge and a first axial abutment face form part of a first surface grouping on a first side of the longitudinal plane, and a second axial relief face adjacent to a second auxiliary cutting edge and a second axial abutment face form part of a second surface grouping on a second side of the longitudinal plane. The first surface grouping and the second surface grouping meet in a partitioning line, wherein the partitioning line extends in the longitudinal plane, and wherein the partitioning line extends from the first side to the second side.