Rotary Cutting Tool Insert Support for Continuous Edge Milling
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Solution Overview
Problem
Existing milling tools with indexable cutting inserts along a single chip flute lack stability in the end station insert, which affects the tool's performance during machining operations.
Innovation Solution
A cutting tool design featuring a cutting body with a forward-rearward direction, where the first and second cutting inserts are removably secured in respective pockets, with a raised shoulder surface providing radial and axial support, allowing for a continuous cutting edge along the chip flute and maximizing the number of chip flutes while maintaining stability through strategic clamping and support configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a plurality of cutting inserts are arranged along a single chip flute to provide a continuous cutting edge, then the productivity and machining efficiency are improved, but the stability and secure positioning of the end station insert deteriorates
Solution Approach 1:
The invention introduces a raised shoulder surface that extends radially outward from the insert seat surface, creating an additional dimensional feature for insert support. This radial extension provides a second contact surface (shoulder surface) in addition to the seat surface, thereby enhancing insert stability while maintaining the continuous cutting edge configuration along the chip flute.
Solution Approach 2:
The raised shoulder surface is nested within the insert receiving pocket structure, forming a stepped configuration where the shoulder surface is located at a different radial position than the seat surface. This nested arrangement allows dual support surfaces to coexist within the confined pocket space, securing the insert from both radial and axial directions.
2Reliability
If the end station insert is secured in the end station pocket, then the insert stability is improved, but the device complexity increases due to additional support structures
Solution Approach 1:
The raised shoulder surface serves multiple functions simultaneously: it provides radial support for the insert, defines the axial position of the insert, and contributes to the continuous cutting edge geometry. This multi-functionality reduces the need for separate support features, thereby limiting the increase in device complexity while achieving enhanced insert stability.
3Reliability
If the raised shoulder surface is positioned radially outward to provide support, then the insert stability is improved, but the area available for chip flute arrangement is reduced
Solution Approach 1:
The insert support function is segmented into two distinct surfaces: the insert seat surface for primary radial support and the raised shoulder surface for additional axial and radial support. This segmentation allows each surface to be optimized for its specific function while minimizing the overall impact on chip flute area, as the shoulder surface utilizes the radial space already defined by the pocket geometry.
Data Source
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AI summary
A rotary cutting tool (20) has a cutting body (22) and a plurality of cutting inserts, including a first insert (24) removably secured in a first pocket and a second insert (26) removably secured in a second pocket. The first pocket opens out at a forward end surface of the cutting body, having a seat surface with an axial support wall (58) transverse thereto, and the second pocket is located axially rearward of the first pocket. The first insert has opposing front and back end surfaces, with a peripheral side surface extending therebetween which is in contact with the seat surface and the axial support wall. A first major cutting edge (42) of the first insert axially overlaps with a second major cutting edge (52) of the second insert, and in a side view of the cutting tool, a raised shoulder surface adjacent the axial support wall is at least partially obscured by the second insert.