Asymmetric Chip Former Cutting Insert for Low Depth Turn
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Solution Overview
Problem
Chip formation becomes challenging at low depths of cut due to varying chip thickness and narrow, thin chips in turning operations, particularly with traditional cutting inserts having rounded corners.
Innovation Solution
A cutting insert with an asymmetric chip former is designed near the rounded cutting corner, varying the distance between the corner and the chip former to account for changing chip thickness and flow angle, ensuring a consistent chip thickness to depth ratio.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a traditional cutting insert with a rounded cutting corner is used, then the insert can perform turning operations, but chip control becomes challenging at low depths of cut due to varying chip thickness and narrow, thin chips
Solution Approach 1:
The patent applies asymmetry by positioning the chip former at different distances from the rounded cutting corner along different directions. Specifically, the distance from the cutting corner to the chip former is greater along the bisector than proximate the cutting edges, creating an asymmetric configuration that compensates for varying chip thickness and improves chip control at low depths of cut
Solution Approach 2:
The chip former is designed with locally varied geometry and positioning relative to the cutting corner. The distance between the cutting corner and chip former varies in different regions (greater along the bisector, less proximate the cutting edges), creating localized conditions that optimize chip formation and control in each specific area of the cut
2Reliability
If the distance between the cutting corner and chip former is varied asymmetrically, then chip control and breakage are improved, but the device geometry becomes more complex
Solution Approach 1:
The asymmetric positioning of the chip former relative to the cutting corner creates different distances in different directions (greater along the bisector, less proximate the edges), which provides consistent chip breakage control without requiring multiple separate components or complex adjustable mechanisms
Data Source
AI summary
A cutting insert includes a top surface, a bottom surface and a plurality of peripheral side surfaces. The top and bottom surfaces and the side surfaces are joined to form rounded cutting corners. A plurality of cutting edges are formed at an intersection between the top surface and the plurality of side surfaces. A pair of asymmetric chip formers are proximate opposite rounded cutting corners. A distance between the opposite rounded cutting corners and the asymmetric chip formers varies in such a way that a ratio of a chip thickness and the distance is substantially constant as a function of a depth of cut.