Miniature Cutting Insert Clamping Trough Geometry
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Solution Overview
Problem
Existing cutting insert technologies face challenges in securely anchoring highly brittle ceramic and PcBN cutting materials, leading to frequent breaking and increased manufacturing costs due to large clamping trough volumes and lack of secure interchangeability.
Innovation Solution
A miniaturized cutting insert with a clamping trough of 2 mm < d1 <= 6 mm and an internal circular nub with a specific geometry, including an inclined flank angle (7° < α1 < 35°) and transition radii, ensures secure clamping and reduced material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the clamping trough volume is reduced to lower manufacturing costs, then the insert size and material cost decrease, but the clamping security and process reliability deteriorate
Solution Approach 1:
The clamping trough is segmented into multiple functional zones: an inclined flank section for pressability, a horizontal section for clamping force transmission, and a bottom section for structural support. This segmentation allows each zone to optimize its specific function while maintaining overall compactness and reliability.
Solution Approach 2:
Different sections of the clamping trough have different geometric properties tailored to their specific functions. The inclined flank provides pressability, the horizontal section provides clamping force transmission, and the bottom section provides structural support. This local optimization enables reduced overall volume while maintaining clamping security.
2Volume of moving object
If the insert size is reduced to decrease manufacturing costs, then material cost decreases, but the clamping security and interchangeability deteriorate
Solution Approach 1:
The clamping trough is nested within the insert body with precise geometric relationships. The trough's inclined flank, horizontal section, and bottom section are integrated into the insert structure, allowing compact design while maintaining secure clamping functionality for interchangeability.
Solution Approach 2:
The clamping trough geometry uses specific parameter ranges: inclined flank angle α1 between 5°-35°, horizontal section length L1 between 0.5-2.0mm, and bottom section radius R1 between 0.1-0.5mm. These optimized parameters enable secure clamping in miniaturized inserts while maintaining interchangeability and reliability.
3Quantity of substance
If the clamping trough volume is minimized, then manufacturing costs decrease, but the ability to securely anchor brittle ceramic and PcBN materials deteriorates
Solution Approach 1:
The inclined flank of the clamping trough is designed to preliminarily guide and prepare the ceramic or PcBN insert during the clamping process. This preliminary action distributes stresses and prevents sudden failure, enabling secure anchoring of brittle materials in miniaturized troughs with reduced volume.
Solution Approach 2:
The bottom section of the clamping trough features a curved geometry with radius R1, and the inclined flank uses smooth transitions. These curved surfaces distribute contact stresses evenly on brittle ceramic and PcBN materials, preventing stress concentration and anchor failure while maintaining compact trough volume.
Data Source
Figure 1~3c
AI summary
The invention relates to a cutting plate (4) for a chip-removing cutting tool, comprising a cutting plate top face (9) and a cutting plate bottom face (10), one or more lateral faces (13), cutting edges (6) at the transition between the cutting plate top face (9) and the one or more lateral face (6), and a circular chip recess (1) in the cutting plate top face (9) that has an outside diameter d1. In order to reduce the production costs, according to the invention the following applies to the outside diameter d1 of the chip recess (1): 2 mm < d1 <= 6 mm, preferably 2 mm < d1 < 5 mm.