Cutting Insert Convex Geometry for Hardened Steel Chip Flow
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Solution Overview
Problem
There is a growing demand for cutting inserts capable of effectively machining workpieces with high hardness, such as hardened steel, which require improved chip discharge performance.
Innovation Solution
A cutting insert design featuring a sintered body with a specific convex portion configuration, including a first convex portion and a second convex portion, which are positioned to control chip flow and enhance chip discharge performance, particularly in machining materials with high hardness and high separability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a sintered body with ultra-high hardness is used to machine hardened steel, then the ability to machine high-hardness materials is improved, but chip discharge performance deteriorates
Solution Approach 1:
The sintered body is designed with a specific convex portion configuration where the first convex portion and second convex portion create distinct local regions with different functions. The first convex portion controls chip flow direction while the second convex portion manages chip discharge, allowing each local region to optimize for its specific function rather than requiring uniform properties throughout the entire cutting insert.
Solution Approach 2:
The chip breaker geometry is designed with asymmetric convex portions that are not symmetrical with respect to the cutting edge. The first convex portion extends in a different direction and has different dimensions compared to the second convex portion, creating an asymmetric structure that optimizes chip flow control and discharge for high-hardness materials like hardened steel.
2Manufacturing precision
If cutting amount is reduced for precision machining, then manufacturing precision is improved, but chip discharge performance worsens
Solution Approach 1:
The convex portions create localized chip control zones that are particularly effective for small cutting amounts. The first convex portion's specific geometry and positioning create a localized flow control region that effectively manages chips even when the cutting depth is minimal, preventing blockage while maintaining precision machining capabilities.
Data Source
AI summary
A cutting insert based on a non-limiting aspect has a first member and a second member joined to the first member. The second member has an upper surface and a side surface adjacent to the upper surface. The upper surface includes a first side, a second side and a corner. The upper surface has a first convex portion extending toward the corner, and a second convex portion extending from the first convex portion toward the first side. The second convex portion has a first end portion and a second end portion located closer to the corner than the first end portion. A first length from the first end to the first side is less than a second length from the second end portion to the first side in a top view.