Wiper Insert Geometry for Accurate Milling and Longer Tool Life
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Solution Overview
Problem
In existing replaceable blade-type milling cutters, wiper inserts with complex shapes face issues with tool life and machining accuracy due to the inability to suppress contact between cutting edges and work materials, particularly when mounted on insert seats with the same shape, leading to a short tool life and reduced accuracy.
Innovation Solution
A wiper insert design featuring polygonal surfaces with specific corner configurations and cutting edges, allowing for rotational symmetry and inward retraction of secondary cutting edges to prevent contact with the work material, enabling stable mounting and extended tool life while maintaining machining accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the wiper insert is designed with a complex shape to suppress contact between cutting edges and work material, then machining accuracy is improved, but the insert mounting seat shape becomes complicated and device complexity increases
Solution Approach 1:
The wiper insert is designed with an asymmetric shape where the major cutting edge is retracted inward in the tool radial direction from the rotation trajectory, while the minor cutting edge protrudes outward. This asymmetric configuration suppresses contact between the major cutting edge and work material during finishing operations, improving machining accuracy without requiring a complicated mounting seat shape.
Solution Approach 2:
The patent inverts the traditional design approach by retracting the major cutting edge (typically the primary cutting element) inward and using the minor cutting edge for cutting operations. This inversion allows the wiper blade to function effectively while preventing harmful contact, resolving the contradiction between accuracy and complexity.
2Manufacturing precision
If the major cutting edge of the wiper insert is disposed to be retracted inward to prevent contact with work material, then machining accuracy is improved, but the side surface cannot come into contact with the wall surface of the insert mounting seat, reducing ease of operation
Solution Approach 1:
The patent introduces a new dimensional solution by providing a restraint surface on the outer peripheral surface of the wiper insert that extends in the tool axial direction. This restraint surface contacts a corresponding surface on the mounting seat, providing mounting restraint in a different dimension (axial direction) rather than relying on radial surface contact, thus maintaining ease of mounting while preserving the retracted major cutting edge configuration.
3Duration of action of moving object
If the wiper insert has a front-back inverted symmetrical shape to extend tool life, then duration of action is improved, but the side surface contact with mounting seat wall surface cannot be achieved, reducing ease of operation
Solution Approach 1:
The patent provides a restraint surface on the outer peripheral surface that extends in the tool axial direction, enabling mounting seat contact in the axial dimension. This allows the wiper insert to achieve front-back inverted symmetrical shape for extended tool life while maintaining ease of mounting through axial surface contact rather than radial contact.
4Adaptability or versatility
If two types of cutting inserts (rough machining and wiper) are mounted on insert mounting seats with the same shape, then adaptability is improved, but the wiper insert cannot suppress contact between cutting edges and work material, reducing manufacturing precision
Solution Approach 1:
The wiper insert employs an asymmetric design with the major cutting edge retracted inward and the minor cutting edge positioned for cutting operations. This asymmetric configuration enables the insert to be mounted on standard mounting seats with the same shape as rough machining inserts, maintaining adaptability while suppressing contact between the major cutting edge and work material to improve machining accuracy.
Data Source
AI summary
A wiper insert includes three first corner portions and three second corner portions which are alternately aligned on a polygonal surface in an insert circumferential direction. A cutting edge has a first cutting edge that performs a finishing operation on a work material, and a second cutting edge. An outer peripheral surface has a first flank face, a second flank face, and a first restraint surface disposed outward from the second cutting edge in an insert radial direction. When viewed in an insert axial direction, an insert shape is rotationally symmetrical by 180° around a rotation center axis passing through the second corner portion adjacent to a first side of a predetermined first corner portion in the insert circumferential direction and an insert center axis.