Star-Rib Cutting Insert Mounting for Fast, Stable Indexing
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Solution Overview
Problem
Existing cutting tools require time-consuming and material-intensive replacement of cutting inserts due to limited use of cutting edges, leading to increased material consumption and longer setup times.
Innovation Solution
A cutting tool design featuring a holder with star-shaped recesses and a cutting insert with odd-numbered ribs and segments, allowing for quick and stable attachment via interlocking ribs and recesses, and a fastening screw for secure connection, which supports angular alignment and thermally induced deformation compensation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If cutting inserts with two cutting edges are used and rotated to extend service life, then setup time is reduced, but material consumption increases and machining stability deteriorates due to angular misalignment
Solution Approach 1:
The cutting insert is divided into an odd number of cutting segments (at least three), allowing multiple cutting edges to be utilized. This segmentation enables the insert to be rotated and reused multiple times before replacement, reducing setup time and material consumption compared to traditional two-edge inserts.
Solution Approach 2:
The cutting insert features an asymmetric rib structure with an odd number of ribs arranged in a star shape around the fastening opening. This asymmetric design, combined with the odd number of ribs, ensures that no two ribs are aligned, creating unique angular positions for each cutting segment that maintains machining stability while enabling multiple uses.
2Loss of time
If cutting inserts with two cutting edges are used and rotated, then setup time is reduced, but machining precision deteriorates due to vibrations from misaligned ribs
Solution Approach 1:
The asymmetric rib arrangement with an odd number of ribs ensures that each cutting segment occupies a unique angular position with no duplicate alignments. This prevents the vibration and instability that occur when symmetric ribs are misaligned during rotation, thereby maintaining machining precision across multiple insert uses.
Solution Approach 2:
Instead of aligning ribs in symmetric patterns that cause vibration when rotated, the invention inverts the approach by using an odd number of ribs where no two are aligned. This inverted design philosophy eliminates the alignment problem entirely, ensuring stable machining regardless of which cutting segment is active.
3Loss of substance
If conventional cutting inserts are used, then material consumption is high requiring frequent replacement, but the odd-numbered rib design complicates the attachment mechanism
Solution Approach 1:
The cutting insert is segmented into an odd number of cutting segments with corresponding ribs, enabling multiple cutting edges to be used before replacement. This segmentation reduces material consumption by extending insert life, and the rib structure provides a straightforward interlocking mechanism with the holder's recesses.
Solution Approach 2:
The holder's recesses are designed with star-shaped geometry that can accommodate the odd-numbered rib configuration. This universal design allows the same holder structure to work with multiple cutting segments, simplifying the overall attachment mechanism despite the unconventional rib arrangement.
Data Source
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AI summary
A cutting tool for machining materials, in particular metal, comprises a holder (10) having a recess (11) for receiving a cutting insert (20), wherein the recess (11) comprises a contact surface (12) extending around a holding bore (13) and in which a plurality of depressions (14) arranged in a star shape around the holding bore (13) are formed, and a cutting insert (20) for connection to the holder (10), wherein the cutting insert (20) has an odd number of cutting segments (21) and, on a side surface (22), an odd number of ribs (24) arranged in a star shape around a fastening opening (23), wherein the ribs (24) are positioned and aligned with one another such that they can penetrate into the depressions (14) of the holder (10).