Reversible Cutting Insert with Curved Minor Surface
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Solution Overview
Problem
Existing cutting inserts for metal cutting operations, particularly 45° shoulder face-milling, suffer from positional deviations and axial bending issues that lead to marring of the work-piece surface due to constant minor cutting edge settings, which are not effectively addressed by current technologies.
Innovation Solution
A double-sided, indexable, and reversible cutting insert with Y-fold rotational symmetry and a clamping through-bore, featuring minor side surfaces with a radius greater than their distance from the through-bore axis, allowing for a wiper edge that maintains machining quality even with positional deviations without requiring grinding of peripheral surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the minor cutting edge has a constant setting angle, then the cutting insert structure is simple and easy to manufacture, but positioning deviation or axial bending causes the wiper corner to mar the work-piece surface
Solution Approach 1:
The patent applies the dynamics principle by making the minor side surface curved instead of straight, allowing the setting angle of the minor cutting edge to vary dynamically. The curved minor side surface is defined by a radius R that is greater than the distance d from the through-bore axis, creating a variable angle geometry that adapts to positional deviations and bending, preventing surface marring while maintaining manufacturing simplicity.
2Reliability
If the corner radius is large (R > d), then the wiper edge maintains functionality with positional deviations, but the insert geometry becomes more complex
Solution Approach 1:
The patent applies the spheroidality principle by defining the minor side surface as a curved surface with a specific radius R. This curvature ensures that the minor cutting edge maintains its wiper function even when positional deviations occur, as the curved geometry provides a range of effective angles. The radius R is specifically designed to be greater than the distance d from the through-bore axis, creating the necessary geometric relationship for reliable performance.
3Manufacturing precision
If grinding is used to reduce positioning deviation, then surface finish quality improves, but manufacturing time and cost increase
Solution Approach 1:
The patent applies the self-service principle by designing the cutting insert geometry itself to compensate for positioning deviations, rather than relying on external processes like grinding. The curved minor side surface with radius R > d creates a self-compensating mechanism where the variable setting angle automatically adjusts to maintain wiper edge functionality, eliminating the need for time-consuming grinding operations while ensuring consistent surface finish quality.
Data Source
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AI summary
A double-sided reversible and indexable cutting insert comprises identical opposing first and second end faces (28) and a peripheral side surface (32) extending therebetween and a clamping through-bore (38) extending between, and opening out to, the first and second end faces, the cutting insert having a median plane extending between the first and second end faces, a through-bore axis extending perpendicularly through the median plane, and an Y-fold rotational symmetry about the through-bore axis; the peripheral side surface comprising Y major side surfaces (34) and Y minor side surfaces, each minor side surfaces interconnecting two adjacent major side surfaces (34); each minor side surface is a section of a single cylindrical surface having a given radius (R), the given radius (R) is greater than a minor side surface distance (D) of each minor side surface from the through-bore axis.