Double-Sided Round Cutting Insert for Stable Multi-Position Indexing
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Solution Overview
Problem
Round cutting inserts for milling tools face limitations in the number of index positions and stability, leading to inefficient machining and reduced service life due to limited rotational lock stability and complex manufacturing requirements.
Innovation Solution
A double-sided round cutting insert design featuring a side surface with double positive clearance surfaces and protrusions that extend radially, providing increased rotational stability and flexibility in indexation, allowing for a larger number of index positions with improved ramping capacity and helical interpolation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If additional locking means are provided on round cutting inserts to improve rotational stability, then stability is improved, but device complexity increases
Solution Approach 1:
The locking function is segmented into multiple discrete protrusions distributed around the insert periphery, each engaging with corresponding depressions in the tool body. This segmentation allows the insert to be locked at multiple index positions (e.g., every 30 degrees) without requiring a complex centralized locking mechanism, thereby improving rotational stability while maintaining relatively simple device structure.
Solution Approach 2:
The protrusions and corresponding depressions are designed to automatically engage when the insert is inserted into the tool body, providing self-locking functionality without requiring additional actuators or complex locking operations. The geometry of the protrusions and depressions ensures proper rotational positioning and stability through simple geometric interlocking.
2Productivity
If the number of index positions is increased by reducing rotation angle between positions, then productivity is improved, but manufacturing precision requirements increase
Solution Approach 1:
The circular periphery of the insert is segmented into multiple discrete index positions by providing multiple protrusions at predetermined angular intervals (e.g., 6 protrusions at 60-degree intervals, or 12 protrusions at 30-degree intervals). This segmentation allows the insert to be quickly indexed to different positions without requiring high-precision rotational adjustment, as each protrusion provides a positive mechanical stop at its designated position.
Solution Approach 2:
The angular spacing between protrusions is optimized to balance the number of index positions with manufacturing feasibility. By selecting appropriate angular intervals (e.g., 30 degrees providing 12 positions), the system achieves high productivity through frequent indexing while maintaining reasonable tolerances for protrusion and depression fabrication, avoiding excessively tight precision requirements.
3Stability of the object's composition
If protrusions extend further in radial direction to improve locking stability, then rotational stability is improved, but device complexity increases
Solution Approach 1:
The protrusions are designed with varying radial extensions at different angular positions around the insert periphery. Each protrusion's radial length is optimized for its specific location and function, allowing some protrusions to extend further for enhanced locking stability in critical positions, while others have shorter extensions where less stability is required. This local optimization improves overall locking stability without uniformly increasing the complexity of the entire insert structure.
Data Source
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AI summary
An indexable and double-sided round cutting insert for a milling tool, the cutting insert comprising an upper side (10) and a lower side (20), wherein a center axis (A) is extending between said upper and lower side (10, 20) and a median plane (P) is extending perpendicular to said center axis (A) and situated halfway between the upper and lower side. A side surface comprises an upper and a lower positive clearance surface (31, 32) at an upper positive clearance angle (α) with respect to an upper cutting edge (41) and a lower positive clearance angle (β) with respect to a lower cutting edge (42), wherein a plurality of protrusions (50) extend along said side surface (30) and protruding in a radial direction perpendicular to said center axis (A) of the round cutting insert. Each protrusion (50) comprising an outer surface (51), which in a direction along said center axis (A) is extending such that a first radial distance from said center axis (A) to said outer surface (51) in the median plane (P) of said insert is at least equal to or greater than a second radial distance from said center axis (A) to said outer surface (51) in parallel planes located closer to said upper or lower side of the round cutting insert.