Double-Sided Negative Cutting Insert for Near-90° Milling Entry
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Solution Overview
Problem
Double-sided negative cutting inserts with conventional designs face challenges due to negative axial and radial tipping-in angles, leading to increased cutting difficulty and reduced entering angles, which are not optimal for efficient machining.
Innovation Solution
A double-sided negative cutting insert with a quadratic basic shape and 90° rotational symmetry, featuring depressed central side surfaces and inclined main cutting edges, improves entering angles and stability, reducing the risk of cutting edge damage and enhancing machining efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a negative axial tipping-in angle is given to the cutting insert, then relief behind the active surface-wiping cutting edge is created, but the cutting process becomes heavier and more difficult
Solution Approach 1:
The patent applies parameter changes by modifying the axial tipping-in angle from negative to positive. This fundamental parameter change transforms the cutting mechanics: the positive axial tipping-in angle reduces cutting resistance and makes the cutting process easier while still providing adequate relief through the combination of positive radial tipping-in angle and optimized cutting edge geometry.
Solution Approach 2:
The patent employs a composite approach by combining positive axial tipping-in angle with positive radial tipping-in angle and specific cutting edge configurations (including rounded corner edges and surface-wiping edges). This composite geometric configuration achieves both relief behind the cutting edge and reduced cutting difficulty simultaneously.
2Reliability
If a negative radial tipping-in angle is given to the cutting insert, then relief behind the active main cutting edge is created, but the entering angle in the workpiece becomes smaller than 90°
Solution Approach 1:
The patent changes the radial tipping-in angle parameter from negative to positive. This parameter change, when combined with the positive axial tipping-in angle, results in an entering angle that approaches 90° more closely, improving the cutting insert's ability to engage the workpiece effectively while maintaining relief behind the cutting edge through the coordinated geometric design.
3Reliability
If the entering angle is kept smaller than 90° due to negative tipping-in angles, then cutting insert clearance is improved, but machining efficiency is reduced
Solution Approach 1:
The patent applies parameter changes by transitioning from negative to positive tipping-in angles, which optimizes the entering angle to approach 90°. This improves machining efficiency and material removal rates. The necessary clearance is simultaneously maintained through the coordinated positive radial tipping-in angle and optimized cutting edge geometry, including the surface-wiping cutting edge design.
Solution Approach 2:
The patent uses a composite geometric configuration combining positive axial tipping-in angle, positive radial tipping-in angle, and specialized cutting edge designs (rounded corners, surface-wiping edges). This composite approach achieves both optimal entering angle for efficiency and adequate clearance for reliable operation.
Data Source
AI summary
A double-sided negative cutting insert for use in milling with quadratic basic shape and eight different working positions is provided. The cutting insert includes a peripheral surface, which extends around the cutting insert between first and second major faces and has four main side faces. One main cutting edge and one surface-wiping cutting edges are formed at an intersection between each main side face and the first major face and at an intersection between each main side face and the second major face. Each main side face includes a first lateral side surface, a central side surface and a second lateral side surface arranged one after the other between two corner side faces with the central side surface located between the first and second lateral side surfaces, wherein the central side surface is slightly depressed in relation to the adjacent first and second lateral side surfaces.