Turning Insert Corner Geometry for Lower Power and Edge Strength

Solution Overview

Problem

Existing cutting inserts for turning operations face a trade-off between robustness and machine power consumption, with large nose angles being robust but power-intensive and small nose angles being weak and prone to heat effects.

Innovation Solution

A cutting insert design with a corner cutting portion featuring a nose angle less than the mid-side angle, comprising mirror-symmetrical nose and narrowing edges, which reduces machine power requirements while maintaining strength, and is manufactured without grinding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a large nose angle is used in the corner cutting portion, then robustness and cutting edge engagement are improved, but machine power consumption increases and vibration propensity increases

Engineering Contradiction:

ImproverobustnessVSAvoidmachine power consumption

Core Design Contradiction:

StrengthVSUse of energy by moving object

Solution Approach 1:

The cutting insert applies local quality by having different nose angles at different locations: the corner cutting portion has a smaller nose angle (50-65 degrees) for reduced power consumption, while the mid-side portions maintain larger angles for robustness. This spatial variation in geometric parameters allows simultaneous optimization of both power efficiency and structural strength.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The cutting insert is segmented into distinct functional zones: corner cutting portions with smaller nose angles and mid-side portions with larger nose angles. This segmentation allows each zone to be optimized independently - corners for power efficiency and mid-sides for robustness - resolving the contradiction between these two requirements.

Inventive Principle:

Principle #1Segmentation

2Use of energy by moving object

If a small nose angle is used in the corner cutting portion, then machine power consumption is reduced, but robustness and resistance to heat effects decrease

Engineering Contradiction:

Improvemachine power consumptionVSAvoidrobustness

Core Design Contradiction:

Use of energy by moving objectVSStrength

Solution Approach 1:

The cutting insert applies local quality by having different nose angles at different locations: the corner cutting portion has a smaller nose angle (50-65 degrees) for reduced power consumption, while the mid-side portions maintain larger angles for robustness. This spatial variation in geometric parameters allows simultaneous optimization of both power efficiency and structural strength.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The cutting insert is segmented into distinct functional zones: corner cutting portions with smaller nose angles and mid-side portions with larger nose angles. This segmentation allows each zone to be optimized independently - corners for power efficiency and mid-sides for robustness - resolving the contradiction between these two requirements.

Inventive Principle:

Principle #1Segmentation

3Use of energy by moving object

If a small nose angle is used in the corner cutting portion, then machine power consumption is reduced, but vulnerability to heat effects increases

Engineering Contradiction:

Improvemachine power consumptionVSAvoidheat effects

Core Design Contradiction:

Use of energy by moving objectVSObject-affected harmful factors

Solution Approach 1:

The cutting insert applies local quality by having different nose angles at different locations: the corner cutting portion has a smaller nose angle (50-65 degrees) for reduced power consumption, while the mid-side portions maintain larger angles for robustness. This spatial variation in geometric parameters allows simultaneous optimization of both power efficiency and structural strength.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The cutting insert is segmented into distinct functional zones: corner cutting portions with smaller nose angles and mid-side portions with larger nose angles. This segmentation allows each zone to be optimized independently - corners for power efficiency and mid-sides for robustness - resolving the contradiction between these two requirements.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS20250222525A1Turning cutting insert with corner cutting portion having reduced nose angle and turning tool

Publication Date: 2025.07.10 ISCAR LTD

AI summary

A cutting tool has an insert holder and a cutting insert releasably attached thereto. The cutting insert has an insert edge which includes two nose cutting edges and a convex corner cutting edge which extends therebetween. The two nose cutting edges form a nose angle. The insert edge also includes two mid-side edges which are located further from the corner cutting edge than the nose cutting edges. The two mid-side edges form a mid-side angle. The nose angle is less than the mid-side angle.