Indexable Milling Insert V-Shaped Valley Positioning
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Solution Overview
Problem
Milling inserts with triangular or trigon shapes face challenges in secure and accurate positioning due to limited points of contact and potential rotation relative to the milling cutter body, leading to instability during machining.
Innovation Solution
A milling insert design featuring a radiused cutting edge with straight components, a V-shaped valley, and facet on the side surface, along with insert mounting structures, ensures secure positioning and resistance to movement by optimizing contact areas and reducing rotational tendencies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a triangular or trigon insert is used with a flat side abutting a side wall of the pocket, then the insert can be mounted in the pocket, but the insert may rotate slightly relative to the walls of the pocket and cannot be properly positioned or maintained in position
Solution Approach 1:
The insert features a convex curved surface on its side that mates with a corresponding concave curved surface in the pocket wall. This curvature design increases the contact area between the insert and pocket, preventing rotation and improving positioning accuracy while maintaining ease of mounting.
Solution Approach 2:
The invention transitions from a simple flat-side abutment (one-dimensional contact) to a curved surface mating geometry (two-dimensional contact area). This dimensional change provides greater contact area and better constraint, eliminating rotational movement while preserving mounting simplicity.
2Reliability
If complex shapes are provided on the bottom surface of the insert to mate with inverse complex shapes on the pocket bottom surface, then movement of the insert is prevented, but these shapes interfere with good contact between side supporting surfaces
Solution Approach 1:
The positioning function is segmented into two independent components: complex interlocking shapes on the bottom surfaces for preventing insert movement, and a separate convex-concave curved surface mating on the side surfaces for ensuring proper positioning and contact. This segmentation allows each feature to perform its specific function without interfering with the other.
Solution Approach 2:
The solution separates the anti-rotation function (handled by bottom surface complex shapes) from the positioning function (handled by side surface curved geometry). By distributing positioning constraints across different dimensions and surfaces, both bottom surface contact and side surface contact can achieve optimal quality simultaneously.
3Strength
If the flat side of the triangular insert abuts the side wall of the pocket, then the insert can be secured, but there are not enough points of contact between the insert and the side wall
Solution Approach 1:
The flat side abutment is replaced with a convex curved surface on the insert that mates with a concave curved surface in the pocket. This curved geometry provides continuous surface contact rather than discrete point contact, increasing both the number of contact points and the total contact area, thereby improving securing force while maintaining positioning precision.
Data Source
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AI summary
The present invention relates milling inserts having surfaces designed for supporting of the insert relative to a milling cutter body, and a milling tool. The milling insert (21) comprises a first end surface (35), a second end surface (37), a side surface (39) extending between the first end surface (35) and the second end surface (37). At least one cutting edge (41) is defined by an intersection of at least one of the first end surface (35) and the second end surface (37) with the side surface (39). The at least one cutting edge (41) comprises a radiused component (45) having a first end (47) and a second end (49) and first and second components (51 and 53) at the first and the second ends (47 and 49) of the radiused component (45), respectively. The first and second components (51 and 53) are less curved than the radiused component (45). The side surface (39) comprises at least one substantially V-shaped valley (59) defined by first and second support surfaces (61 and 63).