Asymmetric Cutting Insert Geometry for Chip Discharge in Shoulder Machining
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Solution Overview
Problem
Existing cutting tools face challenges in improving chip discharge control while maintaining cutting performance, particularly in shoulder machining tools, where conventional designs either neglect chip discharge or compromise on cutting edge angle, leading to poor chip management and potential chip biting.
Innovation Solution
A cutting insert design featuring a recessed inner edge with a longer length on one side and a shorter length on the other, where the lowest point is positioned lower than the upper surface, and the cutting edge angle on the longer side is greater than half of the angle on the shorter side, enhancing chip directionality and separation, and incorporating a wiper edge to improve chip discharge control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the inner edge is positioned lower than the boss surface to improve chip discharge, then chip discharge control is improved, but the engraving amount is reduced
Solution Approach 1:
The inner edge is designed with non-uniform height distribution: the first inner edge portion is positioned lower than the boss surface to improve chip discharge, while the second inner edge portion is positioned at or above the boss surface to maintain engraving capability. This local differentiation resolves the contradiction between chip discharge control and engraving amount.
Solution Approach 2:
The inner edge is segmented into multiple portions (first inner edge portion and second inner edge portion) with different positions relative to the boss surface. This segmentation allows each portion to fulfill different functions: one optimized for chip discharge and the other for engraving, thereby resolving the technical contradiction.
2Productivity
If the cutting edge angle is increased to improve engraving amount, then the engraving amount is increased, but chip discharge control deteriorates
Solution Approach 1:
Different cutting edge angles are assigned to different portions of the inner edge: the first inner edge portion has a smaller cutting edge angle optimized for chip discharge control, while the second inner edge portion has a larger cutting edge angle optimized for engraving amount. This local differentiation resolves the contradiction between these two parameters.
3Ease of manufacture
If the inner edge is made symmetric to simplify manufacturing, then manufacturing is easier, but chip discharge control is poor
Solution Approach 1:
The inner edge is designed with asymmetric geometry where the first inner edge portion and second inner edge portion have different positions relative to the boss surface and different cutting edge angles. This asymmetry optimizes chip discharge control by creating directional chip flow, while the overall structure remains manufacturable through standard machining processes.
Data Source
AI summary
Chip discharge control is further improved. A cutting insert includes an upper surface, a lower surface, a screw hole having an axis penetrating from the upper surface to the lower surface, a peripheral side surface, and a major cutting edge, a wiper edge, and an inner edge formed in an intersecting region between the upper surface and the peripheral side surface. In a side view in which the peripheral side surface on which the inner edge is formed is seen from a direction perpendicular to the axis, the inner edge includes a recessed part recessed toward the lower surface, a length DL of the inner edge on one side of the recessed part in the side view is longer than a length DR of the inner edge on the other side of the recessed part, a lowest point of the inner edge is at a position lower than a flat part of the upper surface, and at least a part of the inner edge on the one side is at a position higher than the flat part of the upper surface. A cutting edge angle φ23L of the inner edge on the one side of the recessed part is larger than a half of a cutting edge angle φ23R of the inner edge on the other side of the recessed part.