Chamfered Throwaway Insert for Chipping-Resistant Regrinding
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Solution Overview
Problem
The existing throwaway inserts suffer from chipping during grinding and cutting, and have limited reuse due to difficulty in maintaining cutting edge quality.
Innovation Solution
A throwaway insert design featuring a base with recesses and a cutting edge member with inclined chamfers and ridgelines, which increases the thickness of the cutting edge member, reducing chipping and allowing for more reuse by facilitating grinding without damaging the base.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If the cutting edge member is made thinner to reduce material usage, then manufacturing cost decreases, but the cutting edge becomes more susceptible to chipping and breakage during grinding and cutting operations
Solution Approach 1:
The patent applies preliminary action by forming a chamfer at the edge tip portion before the cutting edge is put into service. This pre-formed chamfer creates a thicker, more robust edge tip that is less susceptible to chipping during subsequent grinding and cutting operations, while still maintaining material efficiency through the overall thin design of the cutting edge member.
2Manufacturing precision
If the cutting edge member is ground frequently to maintain cutting quality, then cutting precision is maintained, but the base may be damaged due to insufficient thickness
Solution Approach 1:
The chamfer is formed in advance at the edge tip portion, creating a reinforced structure that allows for multiple grinding operations without compromising the base. This preliminary reinforcement enables frequent grinding to maintain cutting precision while preventing base damage.
Solution Approach 2:
The patent applies local quality by providing a chamfer specifically at the edge tip portion where the cutting edge is most vulnerable, while the rest of the cutting edge member maintains its thinner profile. This localized thickening at the critical edge tip area allows for safe grinding operations without unnecessarily increasing material usage throughout the entire cutting edge member.
3Reliability
If the cutting edge member is made thicker to prevent chipping, then reliability improves, but material consumption increases and manufacturing cost rises
Solution Approach 1:
The patent implements local quality by providing a chamfer that increases thickness only at the edge tip portion where the cutting edge is most vulnerable to chipping. The main body of the cutting edge member remains thin, optimizing the balance between durability at the critical edge area and overall material efficiency.
4Ease of manufacture
If the cutting edge member design is simplified to reduce manufacturing complexity, then ease of manufacture improves, but the ability to prevent chipping and enable reuse decreases
Solution Approach 1:
The chamfer is formed as part of the initial manufacturing process or as a preliminary step before the cutting edge is put into service. This preliminary formation of the chamfer integrates smoothly into the manufacturing workflow and provides chip resistance without requiring complex additional structures or processes.
Data Source
AI summary
The throwaway insert includes a base and a cutting edge member. The cutting edge member includes a rake face, a flank face, a first connecting face, a second connecting face, and a first ridgeline serving as a cutting edge. The rake face includes a main surface and a first chamfer provided at an edge tip portion of the cutting edge member, the edge tip portion including an extreme tip portion of the cutting edge member. In a plan view from an upper surface of the base, the flank face, the first connecting face, and the second connecting face are located external to the base. The first chamfer is inclined relative to the main surface so as to increase a thickness of the cutting edge member as the first chamfer is closer to the main surface.