Chip Breaker Geometry for Cutting Inserts With Variable Chip Flow
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Solution Overview
Problem
Conventional cutting tools with ultrahigh-pressure sintered bodies secured to corner parts face limitations in chip disposal capacity, particularly in cutting processes like copy machining where chip flow direction varies, necessitating further improvement.
Innovation Solution
A cutting tool design featuring a cutting insert with ultrahigh-pressure sintered bodies secured to corner parts, incorporating a chip breaker with curved projected and recessed surface parts that enhance chip binding force, allowing for improved chip disposal by bending and separating chips into smaller pieces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a conventional chip breaker with breaker wall surfaces is used, then some chip binding force is achieved, but chip disposal capacity is insufficient especially when chip flow direction varies
Solution Approach 1:
The chip breaker surface is segmented into multiple functional zones: a first projected surface part that contacts chips first, a recessed surface part that receives bent chips, and a second projected surface part. This segmentation allows different portions of the chip breaker to perform different functions (initial contact, bending, lateral separation) thereby improving overall chip disposal capacity and adaptability to varying chip flow directions
Solution Approach 2:
The invention introduces a lateral dimension to chip control by creating a recessed surface part that extends in the lateral direction relative to the cutting edge. This recessed portion allows chips to be bent not only upward but also laterally separated, adding a dimensional aspect to chip disposal that enhances capacity when chip flow direction varies
Data Source
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AI summary
A cutting tool which improves chip disposal capacity is provided. A cutting tool according to the present invention is a cutting tool comprising a cutting edge member which forms at least one corner part, wherein a material for the cutting edge member is selected from either diamond, an ultrahigh-pressure sintered body containing cubic boron nitride or a PVD or CVD coating applied to a surface of the ultrahigh-pressure sintered body. At least part of an intersecting edge between an end surface of the cutting edge member and a peripheral side surface thereof is provided with a cutting edge. A chip breaker comprising a breaker wall surface is formed in the end surface of the cutting edge member. The breaker wall surface has at least one projected surface part which is curved so as to bulge outward from the cutting tool. As viewed from the end surface, the recessed surface part is arranged so as to be apart from a virtual plane A which is defined so as to divide the corner part into halves.