Concave Major Cutting Edge Insert for Lower Chip Thickness
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Solution Overview
Problem
Conventional cutting inserts experience high chip thickness, heat generation, and a risk of fracture due to the 45° or 90° major cutting edge angle, leading to increased impact and reduced durability during milling processes.
Innovation Solution
A cutting insert with a polygonal upper and lower surface, featuring a major cutting edge with a downwardly dented concave shape, including a curvilinear section and straight sections, and varying rake surfaces to manage chip flow and reduce cutting edge angle, enhancing strength and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a cutting edge angle of 45° or 90° is used for the major cutting edge, then the cutting insert can effectively cut the workpiece, but chip thickness increases leading to large impact on the cutting edge
Solution Approach 1:
The cutting edge is designed with non-uniform thickness distribution, creating different local properties along its length. The thicker portions provide strength while thinner portions reduce chip thickness and impact, allowing each section to optimize for its specific function.
Solution Approach 2:
The invention changes the geometric parameters of the cutting edge by introducing a concave curvature profile. This modifies the cutting edge angle dynamically along the length of the cutting edge, transitioning from standard angles to variable angles that reduce chip thickness while maintaining cutting effectiveness.
2Productivity
If a cutting edge angle of 45° or 90° is used for the major cutting edge, then the cutting process can proceed, but large amount of heat is generated during cutting
Solution Approach 1:
By changing the cutting edge geometry to a concave profile with variable thickness, the invention modifies the cutting parameters dynamically. This reduces chip thickness and consequently lowers the heat generated during cutting, while maintaining continuous cutting process capability.
3Productivity
If a cutting edge angle of 45° or 90° is used for the major cutting edge, then the cutting insert can cut the workpiece, but there is a large risk of fracture in the major cutting edge
Solution Approach 1:
The cutting edge features non-uniform thickness distribution with thicker sections providing structural strength and thinner sections reducing chip thickness. This local quality variation ensures that the cutting edge has sufficient strength to prevent fracture while maintaining cutting capability.
Solution Approach 2:
The concave curvature design creates a cushioning effect by gradually reducing chip thickness along the cutting edge. This beforehand cushioning prevents sudden impact loads that could cause fracture, allowing the cutting edge to withstand cutting forces more reliably.
4Productivity
If the cutting edge is curved downward in a side view, then chip thickness increases, but the invention modifies this by creating a concave shape with varying thickness
Solution Approach 1:
The cutting edge employs local quality variation with different thickness sections. The thinner portions effectively control chip thickness to prevent excessive impact, while the overall concave geometry maintains the desired cutting edge profile for productive cutting.
Data Source
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AI summary
A cutting insert (1) according to an embodiment has a lower surface (2), an upper surface (3), a side surface (4) disposed between the lower surface (2) and the upper surface (3), a pair of corner cutting edges (5) located along an intersection of the upper surface (3) and the side surface (4), and a major cutting edge (6) located between the pair of corner cutting edges (5). The major cutting edge (6) has a downwardly dented curvilinear part (61) and a pair of straight parts (62) respectively extending from the curvilinear part (61) toward the pair of corner cutting edges (5) in a side view. A portion (6p) of the curvilinear part (61) located lowermost is close to one corner cutting edge (5b) in the side view.