Square Indexable Cutting Insert with V-Shaped Engagement Ridges
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Solution Overview
Problem
Existing cutting tools with indexable inserts face issues of unacceptably short engagement lengths and ineffective engagement in square-shaped configurations, leading to instability and inaccuracy during metal cutting operations.
Innovation Solution
A single-sided indexable cutting insert with a square shape, featuring four engagement ridges and a central boss, is designed to provide high clamping stability and resistance to transverse forces by using a unique V-shaped cross-section and relief surfaces, allowing for secure mounting in four index positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a square-shaped cutting insert with four sets of female type engagement portions is used, then four index positions are achieved, but the engagement length becomes unacceptably short and engagement becomes ineffective
Solution Approach 1:
The engagement system is segmented into male engagement portions on the holder and female engagement portions on the insert. This segmentation allows the insert to be indexed to four different positions while maintaining effective engagement through the complementary male-female ridge and groove configuration, resolving the contradiction between achieving four index positions and maintaining effective engagement.
2Ease of manufacture
If conventional engagement structures are used, then manufacturing is simpler, but clamping stability and resistance to transverse cutting forces are insufficient
Solution Approach 1:
The engagement ridges and grooves are formed with curved engagement surfaces rather than flat surfaces. This curvature allows the engagement surfaces to conform to each other under load, increasing the contact area and improving resistance to transverse cutting forces while maintaining manufacturability through standard machining operations.
3Productivity
If the cutting insert structure is simplified, then manufacturing efficiency is improved, but rigidity and accuracy are reduced
Solution Approach 1:
The cutting insert is constructed as a composite structure combining a support portion and a cutting portion that can be manufactured separately and then assembled. This composite construction allows each portion to be optimized for its specific function (support for rigidity, cutting edge for precision) while maintaining overall manufacturing efficiency, resolving the contradiction between simplified manufacturing and manufacturing precision.
Data Source
Figure 1
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AI summary
Cutting tool (20) comprises a tool holder (22) having a main body (24) with an insert receiving pocket (26) formed in a front end (28) thereof, and a single-sided square-shaped indexable cutting insert (30) removably secured in the insert receiving pocket (26);the insert receiving pocket (26) comprising: a seating surface (60) having a floor surface (62) with a single engagement groove (64) recessed therein and two separate support pads (66) protruding therefrom; the engagement groove (64) including a pair of parallely extending groove flank surfaces (68) forming a V-shaped cross-section, and each of the two support pads (66) having a raised support surface (70), wherein the two support surfaces (70) are coplanar, and the cutting insert (30) comprising: opposing square-shaped upper and lower surfaces (32, 34) and a peripheral side surface (36). extending therebetween, the peripheral side surface (36) having four corner surfaces (40) alternating with four relief surfaces (42); a central axis (Al) passing through the upper and lower surfaces (32, 34), about which central axis the cutting insert (30) is indexable; and a corner cutting edge (44) formed at the intersection of the upper surface (32) with each of the four corner surfaces (40), the lower surface (34) including a base surface (46) and having exactly four engagement ridges (50) protruding from the base surface (46), wherein each engagement ridge (50) includes a pair of parallely extending ridge flank surfaces (54) forming a V-shaped cross-section, and each engagement ridge (50) intersects one of the four comer surfaces (40) and extends therefrom towards the central axis (Al), wherein the lower surface (34) of the cutting insert (30) is clamped against the seating surface (60) of the insert receiving pocket (26) solely by: the pair of ridge flank surfaces (54) of the engagement ridge (50) located closest to the operative corner cutting edge (44) making contact with the corresponding pair of groove flank surfaces (68) in the single engagement groove (64); and the base surface (46) making contact with the two raised support surfaces (70) at two bearing zones (72) entirely located further from the operative corner cutting edge (44) than the central axis (Al).