Tapered-Waist Indexable Insert for Stable High-Feed Milling
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Solution Overview
Problem
Existing double-sided indexable high-feed and drilling inserts face challenges in tool life expectancy, depth of cut, plunging depth, tool ramping angles, and abutment stability due to limitations in design, particularly with non-winged and winged insert geometries.
Innovation Solution
A double-sided indexable insert with a tapered-waist geometry providing 180-degree rotational symmetry, featuring converging inward and outward abutment surfaces, a through clamping bore, and optimized dimensions for enhanced stability and cutting performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If winged extensions are added to increase cutting edge length, then cutting depth and ramping angles are improved, but the insert becomes more prone to breakage
Solution Approach 1:
The insert is divided into distinct functional zones: winged cutting portions for enhanced cutting performance and a narrow waist section for structural integrity. This segmentation allows each zone to optimize its function while the overall geometry maintains reliability.
Solution Approach 2:
The insert geometry parameters are optimized by controlling the length and curvature radius of the winged extensions relative to the narrow waist section. Specific dimensional relationships ensure the extensions provide cutting advantages without exceeding breakage thresholds.
2Ease of manufacture
If parallel straight side abutment surfaces are used, then manufacturing is simplified, but abutment stability in the pocket is reduced
Solution Approach 1:
The abutment surfaces transition from simple parallel planes to asymmetric converging surfaces that angle toward the centerline. This asymmetric geometry creates mechanical interlocking with the tool pocket, significantly enhancing abutment stability while remaining manufacturable.
3Strength
If a narrow waist section is maintained across the insert length, then structural integrity is improved, but cutting edge length is limited
Solution Approach 1:
The insert geometry utilizes three-dimensional winged extensions that protrude laterally from the narrow waist section. This dimensional approach allows cutting edge length to increase in the lateral direction without compromising the longitudinal structural integrity provided by the narrow waist.
Data Source
Figure 1A~3
Figure 4
Figure 5~8
AI summary
An indexable insert having a 180-degree rotational symmetry about each of the first, second and third axes of a three-dimensional euclidean space, comprising: opposite first and second main surfaces and a peripheral surface extending therebetween, each main surface comprising a main abutment surface and at least two rake surfaces; and a through clamping bore. The peripheral surface comprises two front surfaces formed on opposite sides of a first plane, each comprising a pair of outward abutment surfaces; and two side surfaces formed on opposite sides of a second plane, each extending between the front surfaces, each comprising a pair of at least partially planar inward abutment surfaces. Each pair of inward abutment surfaces converge inwardly towards the third axis. Parallel to the second axis, the insert has a minimum width at inward-most portions thereof, a maximum width at outward-most portions thereof and a width ratio ranges between 1.15 and 1.4.