Stepped Cutting Insert Geometry for Lower Corner Edge Load

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Solution Overview

Problem

Conventional cutting inserts experience reduced service life and increased surface roughness due to processing loads caused by sharply raised corner cutting edges resulting from height differences between main and sub-cutting edges.

Innovation Solution

A cutting insert design featuring first and second cutting edge parts with a corner cutting edge forming a straight line when viewed laterally, inclined upward, and auxiliary cutting edges to minimize processing loads, along with a cutting tool mounted at a negative radial rake angle and positive axial rake angle to enhance connection and reduce interference.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If the corner cutting edge rises sharply due to height difference between main and sub-cutting edges, then the cutting insert can handle stepped geometry, but processing load increases causing reduced service life and increased surface roughness

Engineering Contradiction:

Improvestepped cutting edge geometryVSAvoidservice life of cutting insert

Core Design Contradiction:

ShapeVSReliability

Solution Approach 1:

The patent applies curvature by forming an auxiliary cutting edge that creates a rounded transition between the main cutting edge and sub-cutting edge. This curved geometry eliminates the sharp corner rise, allowing the cutting insert to maintain stepped cutting edge functionality while reducing processing load and improving service life.

Inventive Principle:

Principle #14Spheroidality (Curvature)

2Shape

If the corner cutting edge rises sharply due to height difference between main and sub-cutting edges, then the cutting insert can handle stepped geometry, but surface roughness of workpiece increases

Engineering Contradiction:

Improvestepped cutting edge geometryVSAvoidsurface roughness of workpiece

Core Design Contradiction:

ShapeVSManufacturing precision

Solution Approach 1:

The auxiliary cutting edge with curved transition surface replaces the sharp corner geometry, creating a smooth rounded profile. This curved design eliminates interference with the workpiece during cutting operations, thereby reducing surface roughness while preserving the stepped cutting edge configuration.

Inventive Principle:

Principle #14Spheroidality (Curvature)

3Force

If auxiliary cutting edge is added to connect main and sub-cutting edges, then processing load is reduced, but device complexity increases

Engineering Contradiction:

Improveprocessing load on corner cutting edgeVSAvoidstructure of cutting edge parts

Core Design Contradiction:

ForceVSDevice complexity

Solution Approach 1:

The auxiliary cutting edge is integrated directly into the cutting insert body as a unified structure, merging the connection function between main and sub-cutting edges into the base component. This approach reduces processing load through the curved transition geometry while avoiding additional separate parts, thereby minimizing device complexity.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS11260461B2Cutting insert and cutting tool on which same is mounted

Publication Date: 2022.03.01 KORLOY

AI summary

A cutting insert of the present invention comprises: an upper surface and a lower surface; first and second lateral surfaces; first and second cutting edge parts; and corner cutting edges, wherein the first cutting edge part includes: a first main cutting edge for forming one end at a portion spaced farthest away from the corner cutting edge; a first sub-cutting edge connected to the corner cutting edge; and a first auxiliary cutting edge for connecting the first main cutting edge and the first sub-cutting edge so as to form a step between the same, and the first sub-cutting edge and the corner cutting edge form one straight line when viewed toward the first lateral surface, and are inclined upward in the direction opposite to the direction toward the lower surface while gradually going in the direction toward the second cutting edge part.