Multi-Protrusion Chip Breaker for Stable Cutting Tool Chip Control
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Solution Overview
Problem
Existing cutting tools face challenges in maintaining chip disposal performance across varying depths of cut and in ensuring machined surface accuracy, as chips either spread excessively during shallow cutting or collide with the workpiece during deep cutting.
Innovation Solution
The cutting tool incorporates a chip breaker with multiple protruded portions, including a first and second protruded portion for deep cutting and a third protruded portion for shallow cutting, which are designed to stabilize chip curling and prevent excessive curling or surface collision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the distance from the corner edge to the chip breaker is long, then chip disposal performance deteriorates due to chip spreading during shallow cutting, but machined surface accuracy is improved
Solution Approach 1:
The chip breaker is divided into multiple protruded portions (first, second, and third protruded portions) with different heights and positions. Each portion handles different chip types: the first and second protruded portions handle thick chips during deep cutting, while the third protruded portion handles thin chips during shallow cutting. This segmentation allows the chip breaker to effectively control chips across varying cutting depths without compromising machined surface accuracy.
2Reliability
If the distance from the corner edge to the chip breaker is simply shortened, then chip disposal performance improves, but machined surface accuracy is degraded due to excessive chip curling and collision with the workpiece
Solution Approach 1:
Different portions of the chip breaker have different heights and positions tailored to specific cutting conditions. The first protruded portion has a greater height than the cutting edge to handle deep cutting chips, while the third protruded portion has a lower height to prevent excessive curling during shallow cutting. This local differentiation ensures that each region of the chip breaker optimally addresses the specific chip control needs of its corresponding cutting depth range.
3Device complexity
If a single chip breaker configuration is used, then device complexity is reduced, but adaptability to different cutting depths is poor
Solution Approach 1:
The chip breaker with multiple protruded portions serves multiple functions within a single structure. It can effectively break and control both thick chips generated during deep cutting and thin chips generated during shallow cutting. This multi-functional design eliminates the need for different chip breaker configurations for different cutting depths, making the tool universally applicable across various cutting conditions while maintaining effective chip control.
Data Source
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AI summary
A cutting tool includes a rake face (1), a flank face (2), a cutting edge (3) disposed in a ridgeline portion where the rake face (1) and the flank face (2) are connected and having a V-shape in a plan view of which the rake face (1) is viewed from a front surface, and a chip breaker (4) disposed on the rake face (1). The chip breaker (4) includes a first protruded portion (41) configured to protrude to an upper side from the rake face (1), a second protruded portion (42) configured to protrude to the upper side from the rake face (1), disposed on a rear side of the first protruded portion (41), and extending toward a front side as the second protruded portion (42) is separated from a bisector of the cutting edge (3) in a left-right direction, and a third protruded portion (43) configured to protrude to the upper side from the rake face (1) and disposed on a front side of the first protruded portion (41). The first protruded portion (41) and the second protruded portion (42) further protrude to the upper side than the cutting edge (3), and the height of the third protruded portion (43) is lower than the height of the first protruded portion (41) in an up-down direction.