Concave Corner Turning Insert for Low-Depth Chip Breaking
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Solution Overview
Problem
Existing turning inserts face challenges in achieving effective chip breaking and extended tool life when cutting depths are lower than the nose radius, particularly when machining low carbon steels or hardened steels, often resulting in long or undesirable chip shapes.
Innovation Solution
A turning insert design featuring a corner cutting edge with a 75-85° angle, a concave first surface bordered by cutting edges, and specific transition points and intersection points relative to a bisector, which improves chip control and reduces flank wear by providing a smooth transition between cutting edges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a smaller nose radius is chosen to improve chip breaking at low depth of cut, then chip shape is improved, but the life of the turning insert decreases
Solution Approach 1:
The patent applies local quality by creating a depression (chip breaker) at a specific location on the top surface, adjacent to the corner cutting edge. This localized structural modification provides chip breaking functionality without requiring a smaller nose radius, thus preserving the turning insert life while achieving improved chip shape.
2Shape
If a higher feed is chosen to improve chip breaking, then chip shape is improved, but the machined surface finish deteriorates
Solution Approach 1:
The depression structure is positioned locally adjacent to the corner cutting edge, allowing it to influence chip formation and breaking without interfering with the primary cutting action that determines surface finish. This localized intervention enables improved chip shape while maintaining acceptable surface quality.
3Shape
If high pressure coolant is used to break chips, then chip shape is improved, but the investment cost increases
Solution Approach 1:
The depression structure on the turning insert itself serves as an integrated chip breaker, enabling the tool to break chips through its own geometry rather than relying on external high-pressure coolant systems. This self-service approach eliminates the need for expensive coolant infrastructure while achieving effective chip control.
4Shape
If a chip breaker spaced apart from the active nose cutting edge is used, then chip shape is improved, but the device complexity increases
Solution Approach 1:
The patent merges the chip breaker function with the existing top surface structure of the turning insert. The depression is integrated into the insert body adjacent to the corner cutting edge, combining the cutting edge and chip breaker into a unified structure rather than adding a separate chip breaker component.
Data Source
AI summary
A turning insert includes a top surface, an opposite bottom surface, a side surface connecting the top and bottom surfaces, and a cutting edge formed at an intersection between the top surface and the side surface. The cutting edge including a corner cutting edge, a first cutting edge, and a second cutting edge. The top surface having a first surface in the form of a depression, which borders at least a major portion of the corner cutting edge. The first and the second cutting edges subtending an angle θ which is 75-85°. At least a part of the corner cutting edge is concave in a front view.