Single-Sided Polygonal Cutting Insert for Slot Milling
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Solution Overview
Problem
Existing cutting inserts for slot-milling tools are limited in versatility, as they often require multiple sided configurations and do not efficiently utilize cutting material, leading to poor performance in forming varying slot widths and corner shapes, and do not effectively direct chips away from the generated surface.
Innovation Solution
A single-sided cutting insert with a polygonal body of wear-resistant material, featuring identical cutting corners and a design that allows for varying corner shapes, including radii and chamfers, and incorporates a rake face to direct chips away from the workpiece, with a planar bottom surface and optimized cutting edge geometry for efficient slot milling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple sided configurations are used to achieve versatility for different slot widths, then adaptability is improved, but device complexity increases and cutting material utilization deteriorates
Solution Approach 1:
The cutting insert is designed with four identical cutting corners on a single side, each capable of performing cutting operations. By indexing to different corners, the same insert can mill slots of varying widths, making the insert universal for multiple applications without requiring different inserts or complex multi-sided configurations.
Solution Approach 2:
The cutting insert is divided into four identical cutting corners, each functioning as an independent cutting element. This segmentation allows the insert to be indexed to different corners for different slot widths, providing versatility while maintaining a simple single-sided structure.
2Adaptability or versatility
If different cutting edges are used for right hand and left hand milling, then adaptability is improved, but device complexity increases
Solution Approach 1:
Each cutting corner is designed with asymmetric geometry relative to the insert center, allowing the same corner configuration to function for both right-hand and left-hand milling depending on the direction of rotation and which corner is indexed. This eliminates the need for separate right-hand and left-hand insert designs.
Solution Approach 2:
The identical cutting corners are designed to be universally functional for both right-hand and left-hand milling operations, eliminating the need for different cutting edge configurations and simplifying inventory management.
3Adaptability or versatility
If cutting inserts are designed with specific right hand and left hand embodiments, then adaptability is improved, but ease of operation deteriorates due to potential mix-up
Solution Approach 1:
All four cutting corners are made identical in geometry and configuration, creating a homogeneous insert design. This eliminates the possibility of mix-up between right-hand and left-hand embodiments, as any corner can be used for any milling direction, significantly improving ease of operation.
4Adaptability or versatility
If cutting corners are made rounded to form radii, then adaptability is improved for various corner shapes, but manufacturing precision requirements increase
Solution Approach 1:
The design allows for different corner radius parameters to be selected based on application requirements. By providing four identical corners, the same manufacturing process can produce consistent radii, and the versatility comes from selecting different radius values rather than from complex multi-shape geometries, thereby managing manufacturing precision requirements.
Data Source
Figure 1A
Figure 1B~1C
Figure 2A~2D
AI summary
The present invention relates to a cutting insert (11 ) and a milling tool (10). The cutting insert is to be on-edge mounted to the tool. The cutting insert (11 ) comprises a polygonal body of wear resistant material. The body includes a first side surface and a second side surface opposing one another and therebetween a number of end surfaces. The intersection of two end surfaces form a cutting edge at a corner portion (14). The first side surface is substantially planar and the second side surface connects to raised portions (15) at corner portions (14). The first side surface is greater than the second side surface.