Curvilinear Cutting Insert Edge Design for Chip Clogging
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Solution Overview
Problem
Conventional drills face issues with chip clogging due to the different chip shapes generated by inner and outer cutting edge inserts, leading to inefficient chip discharge and potential tool damage.
Innovation Solution
A cutting insert with a curvilinear cutting edge design, featuring varying radii of curvature for different cutting edges, and a chip discharge flute structure that spirals around the rotation axis, facilitates effective chip discharge and reduces the likelihood of chip clogging by promoting chip cracking and division.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional cutting edge design is used, then the cutting insert can be manufactured with simple geometry, but chip clogging occurs due to excessive chip extension and improper chip discharge
Solution Approach 1:
The cutting edge is designed with a specific curvature radius (R1, R2, or R3) to control chip formation. The curved cutting edge geometry modifies the chip flow pattern and prevents excessive chip extension, thereby eliminating chip clogging while maintaining manufacturability through standardized grinding or machining processes.
Solution Approach 2:
Different regions of the cutting insert have different curvature radii (R1 at first corner part, R2 at second corner part, R3 at third cutting edge). This local variation in geometric properties optimizes chip discharge at each specific location, preventing clogging without requiring complete redesign of the entire insert structure.
2Shape
If the inner cutting edge insert generates chips with shorter pitch, then the chips extend spirally and come together, but this requires specific chip discharge paths and increases system complexity
Solution Approach 1:
The curved cutting edge with specific radius controls the spiral pitch of generated chips. By optimizing the curvature radius, the chip spiral pitch is adjusted to prevent excessive coiling and coming together, enabling natural chip discharge without complex discharge path design.
Solution Approach 2:
The curvature radius parameter (R1, R2, R3) of the cutting edge is varied to control chip morphology. By changing this geometric parameter, the chip spiral pitch and formation characteristics are modified, allowing appropriate chip discharge without increasing system complexity.
3Shape
If the outer cutting edge insert generates chips with longer pitch, then the chips are less likely to come together, but chip clogging may occur when chips excessively extend without being divided
Solution Approach 1:
The cutting edge curvature radius is optimized to balance chip pitch and chip division. The curved geometry promotes controlled chip coiling that prevents both excessive extension and premature coming together, thereby preventing chip clogging while maintaining effective chip discharge.
Solution Approach 2:
The curvature radius parameter is adjusted to control chip morphology. By optimizing this parameter, the chip pitch is controlled to prevent excessive extension, and the curved geometry promotes natural chip division, eliminating clogging without requiring additional chip breaking mechanisms.
Data Source
AI summary
A cutting insert in the present disclosure includes an upper surface, a lower surface, a side surface, and an edge. The upper surface includes a first corner part and a second corner part. The edge is located in a region which is located between the first corner part and the second corner part. The edge includes a first edge located at a side of the first corner part, a second edge located at a side of the second corner part, and a third edge located between the first edge and the second edge. The edge has a curvilinear shape being recessed toward the lower surface in a side view. Each of a radius of curvature R1 of the first edge and a radius of curvature R2 of the second edge is smaller than a radius of curvature R3 of the third edge in a side view.