Polygonal Cutting Insert With Wiper Edges for Surface Finish
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Solution Overview
Problem
Existing indexable cutting inserts are costly and do not provide a high-quality surface finish due to limited cutting edges, requiring frequent tool changes and grinding.
Innovation Solution
A double-sided, polygonal cutting insert with alternating concave and convex cutting edges, providing multiple primary and wiper edges that can be used in a single milling cutter to achieve a high-quality surface finish.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional indexable cutting inserts with limited cutting edges are used, then the cost per edge is high, but the number of cutting edges is limited
Solution Approach 1:
The cutting insert is divided into multiple functional zones with alternating concave and convex cutting edges, allowing each edge to serve a specific cutting function. This segmentation enables multiple cutting edges (16 or more) to be utilized from a single insert, reducing the cost per edge while increasing the quantity of usable cutting edges.
Solution Approach 2:
The cutting insert is designed with alternating concave and convex cutting edges that can all be used in a single right hand style milling cutter, providing both true cutting and wiper functions. This multi-functionality allows one insert to replace what would traditionally require multiple different inserts, increasing the number of usable edges while reducing overall cost.
2Manufacturing precision
If conventional cutting inserts are used, then tool changes and grinding are required frequently, but surface finish quality is insufficient
Solution Approach 1:
The cutting insert features alternating concave and convex cutting edges with different local geometries optimized for specific functions. The concave edges provide true cutting action while the convex edges provide wiper action for superior surface finish. This local quality differentiation allows the insert to maintain high surface finish quality throughout its extended life, reducing tool change frequency.
Solution Approach 2:
The alternating concave and convex cutting edges enable continuous useful action by providing both true cutting and wiper functions within the same insert. This allows the insert to maintain effective cutting performance and surface finish quality throughout extended operation, reducing the frequency of tool changes and grinding operations.
3Adaptability or versatility
If a single milling cutter is used with alternating concave and convex cutting edges, then all cutting edges can be utilized, but the insert geometry becomes complex
Solution Approach 1:
The cutting insert employs alternating asymmetric concave and convex cutting edges, where each edge type has a distinct geometry optimized for its specific function. This controlled asymmetry allows all edges to be used in a single right hand style milling cutter while maintaining the simplicity of the overall insert design through systematic repetition of the alternating pattern.
Data Source
AI summary
A double-sided, polygonal cutting insert includes a first surface and a second surface opposite the first surface. A plurality of side surfaces extend between the first surface and the second surface. A plurality of primary concave cutting edges are formed at an intersection between the plurality of side surfaces and the first and second surfaces, and a plurality of convex wiper edges are formed at an intersection between the plurality of side surfaces and the first and second surfaces. Each wiper edge has a step extending radially outward from a respective side surface. The cutting insert is mounted in a cutting tool such that the primary cutting edge and a wiper edge contact a workpiece to produce a high-quality surface finish on the workpiece.