Stepped Cutting Insert Seat for Stable Heavy-Duty Clamping
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Solution Overview
Problem
Existing tool assemblies for heavy-duty machining face challenges in maintaining insert stability and longevity due to resilient mounting arrangements, which can lead to wear and reduced tool performance under high machining forces.
Innovation Solution
A tool assembly design featuring a specific abutment configuration that applies clamping forces directly to the insert's upper, first lower, and rear abutment surfaces, with a rear relief gap to prevent clamping forces from being directed to the clamp, ensuring that cutting forces are applied to the tool and not the clamp, thereby enhancing stability and longevity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a resilient insert seat is used to retain the insert, then the insert can be easily retained without a clamp, but the machining forces cause wear and reduced tool performance
Solution Approach 1:
The patent extracts the harmful resilient mounting function from the insert seat and replaces it with a rigid seat. The insert is retained through precise geometric abutment surfaces (upper abutment surface, first lower abutment surface, second lower abutment surface, and rear abutment surface) that directly transfer machining forces to the rigid tool body, eliminating the wear-prone resilient connection while maintaining easy insert retention.
2Stability of the object's composition
If a clamp is added to secure the insert to the tool, then insert stability improves, but the device complexity increases
Solution Approach 1:
The patent merges the insert retention function and the force transmission function into a single rigid insert seat structure. The four abutment surfaces work together as an integrated system to simultaneously retain the insert and transmit machining forces directly to the tool body, eliminating the need for a separate clamp component while maintaining insert stability.
3Manufacturing precision
If clamping forces are directed to the clamp through the rear abutment surface, then insert positioning is improved, but the clamp experiences increased wear and reduced longevity
Solution Approach 1:
The patent extracts the force transmission path from the clamp and redirects it through the rigid insert seat. The rear abutment surface of the insert abuts against the rear abutment surface of the rigid insert seat, directing clamping forces and machining forces directly to the tool body rather than through the clamp, thereby preserving clamp longevity while maintaining precise insert positioning.
Data Source
Figure 1A~1C
Figure 2A~2D
Figure 2E~2G
AI summary
Single-cutting-edged solid cutting insert (12) with a step in the lower portion. The insert comprises: opposite insert first and second side surfaces (28A; 28B); an insert plane (PI) parallel with and located midway between the insert side surfaces (28A; 28B); an insert peripheral surface (30) connecting the insert side surfaces (28A; 28B); a first corner region (R1) located in an upper-rear portion of the cutting insert; a second corner region (R2) located in an upper-front portion of the cutting insert; a third corner region (R3) located in an lower-front portion of the cutting insert; and a fourth corner region (R4) located in an lower-rear portion of the cutting insert. T he insert peripheral surface (30) comprises: a peripheral upper sub-surface (30A) extending from the first corner region (R1) to the second corner region (R2); a peripheral front sub-surface (30B) extending from the second corner region (R2) to the third corner region (R3); a peripheral lower sub-surface (30C) extending from the third corner region (R3) to the fourth corner region (R4); and a peripheral rear sub-surface (30D) extending from the fourth corner region (R4) to the first corner region (R1). T he first corner region (R1) comprising: an insert upper abutment surface (32A) formed at the peripheral upper sub-surface (30A) and extending forward of the peripheral rear sub-surface (30D); and an insert rear abutment surface (32B) formed at the peripheral rear sub-surface (30D) and extending downward of the peripheral upper sub-surface (30A). T he second corner region (R2) comprises: a single cutting edge (34) only, the single cutting edge connecting the insert side surfaces (28A; 28B) and being wider than adjacent portions of the peripheral upper and front sub-surfaces (30A; 30B). T he third corner (R3) comprises: an insert first lower abutment surface (32C) formed at the peripheral lower sub-surface (30C) and extending rearward of the peripheral front sub-surface (30B); and an insert second lower abutment surface (32D) formed at the peripheral lower sub-surface (30C) and extending downward of the insert first lower abutment surface (32C).