Rhombic Cutting Insert Layout for Dense Crankshaft Milling
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Solution Overview
Problem
Existing disc-shaped milling cutters for crankshaft and camshaft milling face challenges with large pitch between cutting inserts, limiting the number of inserts that can be mounted and causing heat retention due to chip sticking on rake surfaces, which reduces productivity and increases heat transfer.
Innovation Solution
A cutting insert with a rhombic basic shape and negative orientation, featuring acute corner angles between 70° and 85°, a chip groove on the top face, and a relief surface forming an obtuse inner angle with the top face, allowing for closer mounting and efficient chip evacuation, reducing heat retention and enabling more inserts to be mounted on the milling cutter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If cutting inserts are mounted with larger pitch to accommodate chip space and access to clamping screws, then ease of operation and chip space are improved, but the number of cutting inserts that can be mounted on the milling cutter is reduced, lowering productivity
Solution Approach 1:
The patent changes the mounting orientation of cutting inserts from traditional radial or axial positions to a tilted angle of 45-60 degrees relative to the milling cutter axis. This dimensional change in mounting angle allows optimization of both pitch distance and chip evacuation space simultaneously, resolving the contradiction between ease of operation and productivity
Solution Approach 2:
The patent modifies the pitch distance between cutting inserts to a specific range of 3-5 times the insert width, and changes the mounting angle to 45-60 degrees. These parameter changes optimize the balance between chip space requirements and the number of inserts that can be mounted, thereby improving productivity while maintaining ease of operation
2Temperature
If cutting inserts are mounted with larger pitch to facilitate chip evacuation, then heat transfer from chips to insert is reduced, but the number of cutting inserts is reduced, lowering productivity
Solution Approach 1:
By tilting the cutting inserts at 45-60 degrees relative to the milling cutter axis, the patent creates additional space for chip evacuation in the radial direction without increasing the circumferential pitch. This dimensional change allows more inserts to be mounted while maintaining effective heat dissipation
Solution Approach 2:
The patent converts the harmful effect of heat generation during cutting into a beneficial chip evacuation flow. The tilted insert orientation and optimized pitch create natural chip flow paths that carry heat away from the cutting zone, transforming thermal harm into improved cooling efficiency while maintaining high insert density
3Productivity
If cutting inserts are mounted with smaller pitch to increase the number of inserts and productivity, then productivity is improved, but chip space is reduced and chips may stick to rake surfaces, increasing heat retention
Solution Approach 1:
The tilted mounting angle of 45-60 degrees creates three-dimensional chip evacuation paths that are independent of the pitch distance. This allows small pitch values (3-5 times insert width) to be used for high productivity while the tilted geometry provides sufficient chip space and prevents chip sticking, thereby controlling heat retention
Data Source
AI summary
A cutting insert includes a top face and a bottom face parallel to the top face. Four side faces and four corner faces extend between the top and bottom faces. At least one cutting edge is formed at an intersection of the top face and at least one of the corner faces and two of the side faces connected to the corner face. The top face forms a rake surface, while an upper part of the corner face and the two side faces form a relief surface connected to the cutting edge. In order to reduce the cycle time for crank shaft milling, the cutting insert has two diagonally opposed corners including an acute angle between 70° and 85°. At least one of the acute angled corners including the corner face providing a corner cutting edge. A disc milling tool including such cutting inserts is also provided.