Tangential Cutting Insert with Multiple Major Sides
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Solution Overview
Problem
The manufacturing of tangential indexable cutting inserts with positive axial rake is complex due to the presence of undercuts, making straightforward pressing and sintering methods impossible, limiting their application in milling tools.
Innovation Solution
A single-sided, fully indexable tangential cutting insert with multiple identical major sides and a unique cutting edge configuration that allows for straightforward pressing and sintering, featuring a peripheral side surface with N major sides, each with a cutting edge formed at the intersection of a relief and rake surface, and a corner cutting edge extending towards the bottom surface, enabling greater cutting force resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional pressing and sintering methods are used to manufacture cutting inserts, then the manufacturing process is straightforward and simple, but it is impossible to manufacture inserts with undercuts required for positive axial rake and multiple cutting edges
Solution Approach 1:
The patent transitions from traditional 2D flat cutting insert designs to 3D geometric forms with multiple cutting edges (3-8 edges) arranged around the periphery. This dimensional change allows the insert to achieve complex geometries including undercuts and positive axial rake angles while remaining compatible with straightforward pressing and sintering manufacturing methods. The peripheral arrangement of multiple cutting edges on a single side enables full indexability without requiring reversible or double-sided designs.
2Ease of operation
If radially mounted cutting inserts are used, then the cutting forces are directed along the thinner dimension, but the insert can withstand smaller cutting forces
Solution Approach 1:
The patent employs asymmetric geometric design where the cutting edges are arranged tangentially around the periphery rather than radially. This asymmetric arrangement ensures that cutting forces are consistently directed along the thicker, stronger dimension of the insert body during operation. The tangential configuration with multiple cutting edges positioned at different angular locations around the periphery optimizes force distribution and maximizes the insert's load-bearing capacity while maintaining operational effectiveness.
3Adaptability or versatility
If cutting inserts with positive axial rake and multiple cutting edges are manufactured, then the tool performance and versatility are improved, but the manufacturing complexity increases due to undercuts
Solution Approach 1:
The patent applies preliminary action by designing the cutting insert geometry and tool holder configuration to work together from the outset. The insert is pre-configured with multiple cutting edges arranged tangentially on a single side, and the tool holder is designed with corresponding pockets and location surfaces that accommodate this geometry. This preliminary integration eliminates the need for complex post-manufacturing operations or specialized tooling, allowing straightforward pressing and sintering to produce the final functional insert without requiring undercut removal or complex assembly steps.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution allows for the efficient manufacturing and use of tangential cutting inserts that can withstand greater cutting forces, providing improved surface finish and versatility in milling operations without the need for complex dies, facilitating easier production and increased tool performance.
Implementation Method 1
A cutting edge is formed at the intersection of a relief surface and a rake surface... the major cutting edge is adapted to mill a shoulder in a workpiece
Implementation Method 2
at least a section of the adjacent auxiliary cutting edge acts as a wiper to provide a good surface finish
Implementation Method 3
Such cutting inserts are generally considered to be 'pressed and sintered cutting inserts'... The cutting insert may be manufactured by straightforward pressing and sintering
Implementation Method 4
The cutting insert may be made by uni-axially form-pressing carbide powders using a non-split single-axis die to form an insert green body of suitable shape
Data Source
Figure 1~2
Figure 3~4
Figure 5~7
AI summary
A single- sided tangential cutting insert (10) has a peripheral side surface (16) with N identical major sides (18). The cutting insert (10) has 360°/N rotational symmetry about an insert axis (A) passing through top and bottom surfaces (12, 14) of the insert (10), where N is an integer greater than 2 and each major side (18) is located between and merges with an adjacent major side (18). A cutting edge (20) is formed at the intersection of a relief surface (22) and a rake surface (24, figure 2). The rake surface (24) is located in the peripheral side surface (16) and extends in an inward direction of the cutting insert (10) from its associated cutting edge (20) to a side surface (44) of the associated major side (18). At least a portion of the relief surface (22) is located in the top surface (12).