Single-Sided Ramping Milling Insert With Relief Depression
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Solution Overview
Problem
Existing ramping milling tools face limitations in achieving high ramping angles and efficient machining due to insufficient relief and robustness, particularly during ramping operations, leading to reduced performance and potential tool breakage.
Innovation Solution
A single-sided indexable ramping milling insert with a depression between lowered corner cutting edges and bottom corner edges, providing convex curvature and relief, which allows for increased ramping angles and improved machining efficiency by preventing unwanted contact with the workpiece surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional ramping milling tools are used, then the tool structure is simple, but the ramping angle is limited and machining efficiency is reduced
Solution Approach 1:
The insert is divided into multiple functional zones with different cutting edge configurations. The top edge has side cutting edges for profiling, while the bottom edge has corner cutting edges for ramping. This segmentation allows each zone to perform its specific function optimally, enabling high ramping angles while maintaining structural clarity.
Solution Approach 2:
The invention introduces a vertical dimension to the cutting edge arrangement by having cutting edges on both the top and bottom edges of the insert. This three-dimensional configuration of cutting edges allows the tool to achieve high ramping angles by utilizing the bottom corner cutting edges that extend below the top cutting edges, thereby increasing productivity without excessive complexity.
2Productivity
If high ramping angles are achieved, then machining efficiency improves, but the risk of tool breakage and unwanted contact increases
Solution Approach 1:
Different regions of the insert are given different geometric properties suited to their specific functions. The bottom corner cutting edges are positioned and shaped to provide relief from unwanted contact with the workpiece during high-angle ramping, while the side cutting edges maintain profiles. This localized optimization allows high ramping angles (improving productivity) while preventing tool breakage (maintaining reliability).
Solution Approach 2:
The bottom corner cutting edges are designed with specific geometry that preemptively prevents unwanted contact with the workpiece surface during ramping operations. By anticipating the potential harmful contact and designing the cutting edge geometry to avoid it, the tool can operate at high ramping angles without the risk of breakage, thus maintaining both productivity and reliability.
3Reliability
If bottom corner cutting edges are added, then relief from workpiece surface is improved, but manufacturing complexity increases
Solution Approach 1:
The bottom corner cutting edges are integrated into the same insert body as the top cutting edges, forming a unified tool component. This merging of functions into a single indexable insert allows the tool to achieve relief from unwanted workpiece contact while avoiding the need for separate components, thereby maintaining ease of manufacture despite the enhanced functionality.
Data Source
Figure 1~2
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Figure 8~10
AI summary
A single-sided ramping milling insert (14) for ramping operations has top and bottom surfaces (20,22) and a peripheral surface (24) which extends therebetween. The peripheral surface (24) meets the top and bottom surfaces (20,22) at respective top and bottom edges (28,30). The top edge (28) includes two opposite side cutting edges (32), two opposite ramping cutting edges (30), two diagonally opposite raised comer cutting edges (44) and two diagonally opposite associated lowered comer cutting edges (54). The lowered comer cutting edges (54) are closer to the bottom surface (22) than the raised comer cutting edges (44). The bottom edge (30) has two diagonally opposite bottom comer edges (64). The lowered comer cutting edges (54) and the bottom comer edges (64) are convexly curved and a depression (66) is recessed into the peripheral surface (24) between each lowered comer cutting edge (54) and its associated bottom comer edge (64), the depression (66) configured for providing relief from a convex workpiece surface cut by the lowered comer cutting edge (54) during ramping operations.