Convex Cutting Insert Geometry for Burr Reduction
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Solution Overview
Problem
Conventional cutting inserts with straight edges often leave undesirable burrs on machined surfaces, leading to misalignment, safety issues, and increased deburring time and costs, as existing cutting insert designs do not effectively reduce burr formation during machining.
Innovation Solution
A cutting insert with a substantially horizontal cylindrical segment shape featuring convex top and bottom cutting edges, a circular segment shape, and a hole extending from the convex side to the flat side, which reduces burr formation by altering the cutting edge geometry and stress distribution during machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional straight cutting edges are used, then the cutting insert structure is simple and easy to manufacture, but burr formation increases significantly
Solution Approach 1:
The cutting edge is designed with a convex curved shape instead of a straight line, creating a spherical or arc-shaped cutting surface that rolls over the workpiece material. This curvature allows the cutting edge to gradually engage and disengage from the material, preventing sudden material displacement that causes burrs, while maintaining manufacturability through standard grinding and machining processes
2Object-generated harmful factors
If convex curved cutting edges are implemented, then burr formation is reduced, but the cutting insert design complexity increases
Solution Approach 1:
The invention modifies the geometric parameters of the cutting edge by introducing a specific convex curvature radius (R) that ranges from 0.1 to 10 times the insert thickness. This parameter optimization balances the curvature effect for burr reduction while keeping the geometry within manufacturable limits, avoiding excessive complexity in design and fabrication
3Object-generated harmful factors
If convex curved cutting edges are used, then burr thickness decreases, but Von Mises stresses increase
Solution Approach 1:
The convex curved cutting edge performs preliminary plastic deformation on the material ahead of the main cutting action, gradually compressing and densifying the material in the exit zone. This preliminary action prepares the material for cleaner separation, reducing burr formation while the increased stress is confined to a controlled zone that does not compromise overall tool performance
Data Source
AI summary
A cutting insert of a substantially horizontal cylindrical segment shape is described. The cutting insert comprises top and bottom surfaces having a circular segment shape. The cutting insert further comprises a convex side. The cutting insert further comprises a flat side. The cutting insert further comprises a top cutting edge which is formed where the convex side and the top surface meet, and a bottom cutting edge which is formed where the convex side and the bottom surface meet. The cutting insert further comprises a hole extending from the convex side towards the flat side. The hole is positioned at a center of a surface of the flat side.