Monolithic Tangential Cutting Insert with Star-Shaped Edges
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Solution Overview
Problem
Tangential cutting inserts in prior art are mechanically weak due to small contact surfaces between cutting edge bodies and the main body, limiting their load capacity and requiring complex and costly production processes with multiple joining operations.
Innovation Solution
Producing a tangential cutting insert entirely from hard materials like cubic crystalline boron nitride, polycrystalline diamond, or ceramic, eliminating the need for joining operations and allowing for a one-piece design with a star-shaped arrangement of cutting edges, enhancing mechanical stability and ease of production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If cutting edge bodies are joined to the main body in prior art tangential cutting inserts, then the cutting insert can be produced with separate hard cutting edges, but the joints become mechanical weak points that restrict operating parameters and reduce reliability
Solution Approach 1:
The patent merges the cutting edge bodies and main body into a single integrated component made entirely from hard material (cubic crystalline boron nitride, polycrystalline cubic boron nitride, polycrystalline diamond, or ceramic). This eliminates the joints between separate cutting edge bodies and the main body, removing the mechanical weak points that limited load capacity and reliability in prior art designs.
Solution Approach 2:
The patent uses entirely hard materials (cubic crystalline boron nitride, polycrystalline cubic boron nitride, polycrystalline diamond, or ceramic) for the complete cutting insert structure. This composite approach with uniform hard material throughout eliminates the need for joining different materials, thereby eliminating joints and improving both mechanical stability and load capacity.
2Manufacturing precision
If multiple joining operations are performed to attach cutting edge bodies to the main body, then the cutting insert can be assembled with precise positioning, but the production process becomes complex and costly
Solution Approach 1:
The patent combines the cutting edge bodies and main body into a single monolithic component made from hard material. This eliminates the need for multiple joining operations and associated positioning steps, dramatically simplifying the manufacturing process while maintaining precision through the inherent accuracy of monolithic fabrication.
Solution Approach 2:
The patent eliminates segmentation into separate joinable parts by creating a single integrated cutting insert. The star-shaped cutting edges are formed as one piece from the hard material, removing all joining operations and positioning requirements that complicate manufacturing in prior art designs.
3Strength
If cutting edge bodies are soldered or sintered to the main body, then the cutting insert can be assembled with secure attachment, but the contact surface remains small and the joints become weak points
Solution Approach 1:
The patent merges the cutting edges and main body into a single continuous structure made from hard material. This eliminates soldered or sintered joints entirely, providing uniform mechanical stability throughout the entire cutting insert without the small contact surfaces that create weak points in joined constructions.
Data Source
AI summary
A tangential cutting insert for a turning tool is described, which comprises a first tangential cutting insert side and a second tangential cutting insert side, wherein one of the tangential cutting insert sides is assigned more than two cutting edges, and the cutting edges are arranged in a star shape about a tangential cutting insert center axis. The tangential cutting insert is produced completely from cubic crystalline boron nitride, polycrystalline cubic boron nitride, polycrystalline diamond, or ceramic. In addition, a cutting tool with such a tangential cutting insert is presented. A method for producing a tangential cutting insert is also explained.