CBN Cutting Insert Geometry for Stable Chip Disposal in Hardened Steel
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Solution Overview
Problem
Cutting tools with ultra-high pressure sintered bodies face instability in chip disposal during high hardness material processing, particularly in hardened steel, due to uneven hardness surfaces and inadequate breaker wall surfaces.
Innovation Solution
A cutting insert design featuring a sintered body of cubic boron nitride or diamond with a unique surface geometry, including inclined regions and a specific chip discharge configuration, enhances chip discharge performance by curving and stabilizing chip flow, reducing the likelihood of chip clogging and improving durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If the width of the honed surface is increased or the honing angle is increased to enhance durability for cutting high hardness material surfaces, then durability is improved, but chip disposal stability deteriorates because chips flow along the honed surface without proper handling
Solution Approach 1:
The honed surface is divided into multiple regions with different functions: a first region with a first honing angle for durability, and a second region with a second honing angle for chip disposal. This segmentation allows each region to optimize its function independently, resolving the contradiction between durability and chip disposal stability.
Solution Approach 2:
Different portions of the honed surface are given different properties through varying honing angles. The first region has a larger honing angle for durability when cutting hard surfaces, while the second region has a smaller honing angle to prevent chip adhesion and improve chip disposal stability. This local differentiation resolves the contradiction by applying appropriate properties to specific locations.
2Stability of the object's composition
If the breaker wall surface is positioned low and away from the cutting edge to maintain structural integrity, then structural stability is improved, but chip handling capability deteriorates because the breaker wall surface cannot effectively handle unstable chips
Solution Approach 1:
The breaker wall surface is extended in the radial direction to create a multi-level structure with a first breaker wall surface and a second breaker wall surface at different heights. This dimensional extension allows the breaker wall to effectively handle chips at multiple levels without compromising structural stability, resolving the contradiction between structural integrity and chip handling capability.
3Productivity
If a large honing angle is used to cut through high hardness material surfaces effectively, then cutting capability is improved, but chip flow control deteriorates causing unstable chip disposal
Solution Approach 1:
The honed surface is segmented into regions with different honing angles: the first region has a larger angle for effective cutting of hard surfaces, while the second region has a smaller angle for stable chip flow control. This segmentation resolves the contradiction by assigning different angular properties to different functional zones.
Solution Approach 2:
The chip flow path is dynamically controlled by the varying honing angles across different regions. Chips generated at the cutting edge are guided through the first region with larger angle for initial separation, then through the second region with smaller angle for stable flow and disposal, creating a dynamic chip control system that adapts to different cutting stages.
Data Source
AI summary
A cutting part of a cutting insert may include a first surface including a corner, a first side, a first region, a second region and a third region. The first region may be located along the corner and the first side. The second region may be located at a more inner part than the first region. The third region may be located at a more inner part than the second region. A boundary between the corner and the first side may be a first point. A boundary between the first region and the second region may be a second point in a cross section that passes through the first point and is orthogonal to the first side. An imaginary straight line passing through the first point and the second point may be a first imaginary straight line. The first imaginary straight line may intersect with the third region.