Symmetric Cutting Insert Geometry for Uniform Milling Surfaces
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Solution Overview
Problem
Existing end mills face challenges in achieving uniform processing surface accuracy during face-milling and side-milling processes due to varying kerf marks across different processing portions and shapes of work materials.
Innovation Solution
A cutting insert with a plate-shaped insert main body featuring a bottom cutting edge and an outer peripheral cutting edge, both forming arc shapes with equal curvature radii, and a cutting edge of corner R, which are symmetrically arranged and connected to ensure uniform processing surface quality by forming congruent rectangular triangles, allowing for consistent kerf marks across different processing surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional end mills with separate bottom and outer peripheral cutting edges are used, then face-milling and side-milling processes can be performed, but the processing surface accuracy becomes non-uniform across different processing portions
Solution Approach 1:
The invention applies asymmetry by making the bottom cutting edge and outer peripheral cutting edge asymmetric with respect to the central axis, where the bottom cutting edge has a larger curvature radius than the outer peripheral cutting edge. This asymmetric design compensates for the different cutting conditions in face-milling and side-milling, enabling uniform processing surface accuracy across different processing portions.
2Productivity
If different curvature radii are used for bottom and outer peripheral cutting edges, then cutting performance for different processes is optimized, but processing surface quality becomes inconsistent
Solution Approach 1:
The invention changes the curvature radius parameter of the cutting edges based on the processing portion. Specifically, the bottom cutting edge has a curvature radius of 0.05D to 0.2D while the outer peripheral cutting edge has a curvature radius of 0.01D to 0.05D (where D is the tool diameter). This parameter change optimizes cutting performance for different processes while maintaining uniform processing surface quality through the asymmetric relationship between the two cutting edges.
Data Source
AI summary
A cutting insert includes a cutting edge portion, and the cutting edge portion includes a bottom cutting edge forming an arc shape that protrudes toward a front end side in a central axis direction, an outer peripheral cutting edge forming an arc shape that protrudes toward an outside in a radial direction, and a cutting edge of corner that connects an outer end of the bottom cutting edge in the radial direction and a front end of the outer peripheral cutting edge in the central axis direction and forms an arc shape that protrudes toward a front end outer circumferential side. The bottom cutting edge and the outer peripheral cutting edge are formed so as to form a linearly symmetric shape together with respect to an imaginary straight line that passes through an arc central point of the cutting edge of corner and intersects the central axis.