Double-Sided Tangential Cutting Insert With Convex Minor Edges
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Solution Overview
Problem
Existing double-sided tangential cutting inserts face challenges in achieving balanced surface finish and perpendicularity between machined surfaces due to complex cutting edge geometry, particularly on minor cutting edges, leading to difficulties in slot milling and other machining processes.
Innovation Solution
The design features a double-sided tangential cutting insert with convex minor cutting edges having a large radius, a single full nose cutting edge, and a main cutting edge truncated by the adjacent convex minor side face, which enhances surface finish and adaptability to machining irregularities such as tool holder deflections and tolerance variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If complex cutting edge geometry is used on minor cutting edges, then cutting insert design flexibility is improved, but surface finish quality and perpendicularity deteriorate
Solution Approach 1:
The patent applies curvature by designing convex minor cutting edges with a large radius of curvature instead of straight or sharp edges. This curved geometry naturally adapts to tool holder deflections and workpiece tolerance variations while maintaining consistent surface finish quality and perpendicularity, resolving the contradiction between design flexibility and machining precision.
2Ease of manufacture
If straight minor cutting edges perpendicular to main cutting edges are used, then manufacturing simplicity is improved, but adaptability to machining irregularities deteriorates
Solution Approach 1:
The patent replaces straight minor cutting edges with convex curved edges having a large radius. This curvature provides adaptability to machining irregularities such as tool holder deflections and tolerance variations, while the convex shape remains manufacturable using standard forming processes, balancing manufacturing simplicity with operational adaptability.
3Measurement precision
If small radius cutting edges are used, then cutting edge sharpness is improved, but tolerance to deflections and variations deteriorates
Solution Approach 1:
The patent uses a large radius of curvature for the convex minor cutting edges instead of small radii. This larger curvature radius provides tolerance to deflections and variations during machining, while the convex geometry maintains sufficient cutting edge sharpness for effective material removal, resolving the contradiction between edge sharpness and tolerance to irregularities.
Data Source
AI summary
A double-sided tangential cutting insert, as well as a tool holder system that carries a plurality of the double-sided tangential cutting inserts, that has a peripheral side shape, as viewed from one of said cutting rake faces, that includes a pair of generally identical opposing main cutting edges wherein each of the main cutting edge comprises a substantially straight main cutting edge portion and an adjoining convex main cutting edge portion. The convex main cutting edge portion is truncated by an adjacent convex minor side face so as to define a generally sharp edge and a point of truncation. The peripheral side shape further includes a pair of opposing full nose cutting edges with a nose cutting radius; and a pair of opposing convex minor cutting edges with a minor cutting edge radius. The minor cutting edge radius is at least about four times greater than the nose cutting radius.