Cutting Element Segmentation for Friction Reduction
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Solution Overview
Problem
Conventional cutting tools face challenges in efficiently removing material below a certain thickness, leading to increased friction and heat generation, as the cutting edge struggles to maintain effective contact with the workpiece due to reduced chip thickness.
Innovation Solution
The introduction of a cutting member with a cutting edge comprising a first and second cutting segment, an adjoining segment, and auxiliary cutting elements that extend along imaginary tangents, allowing for partial material removal and reducing friction by avoiding contact with the bisector and material wave, thereby alleviating stress and heat issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the cutting edge maintains contact with the workpiece to remove material, then material removal efficiency is improved, but friction and heat generation increase when chip thickness is reduced
Solution Approach 1:
The cutting edge is divided into multiple segments (first cutting segment, second cutting segment, and adjoining cutting segment) with different functions. The first and second segments are positioned to avoid contact with material waves, while the adjoining segment bridges between them. This segmentation allows the cutting edge to maintain material removal capability while reducing friction and heat generation by strategically positioning segments to avoid harmful contact zones.
2Manufacturing precision
If the cutting edge is designed to remove material below certain thickness, then cutting precision is improved, but the cutting edge struggles to maintain effective contact with the workpiece
Solution Approach 1:
Different segments of the cutting edge are designed with distinct local qualities and positions. The first and second cutting segments are positioned at specific locations relative to the workpiece surface and material waves, while the adjoining segment connects them. This local quality differentiation enables precise material removal at varying thicknesses while maintaining reliable contact effectiveness through strategic segment positioning.
Data Source
AI summary
A cutting member comprising a cutting edge (S1,S2,Si) defining a cutting envelope and configured for removing material from a workpiece leaving therein a corner of angle α. The cutting edge comprises a first cutting segment (S1) and a second cutting segment (S2) spaced from the first cutting segment (S2). Respective first and second imaginary tangents (T1,T2) of the first and second cutting segments (S1,S2) intersect one another at point O located outside the cutting envelope, forming an angle corresponding to angle α, thereby defining a cutting frame at least a portion of which extends beyond the cutting envelope. The cutting edge further comprises an adjoining cutting segment (Si), extending between and bridging the first cutting segment (S1) and the second cutting segment (S2), and at least partially contained within the cutting frame. The cutting member further comprises at least one auxiliary cutting element (AT1,AT2) comprising an auxiliary cutting edge (CE′,CE″) extending generally along one of the imaginary tangents (T1,T2) and beyond the cutting envelope. The auxiliary cutting edge (CE′,CE″) does not intersect the other of the imaginary tangents (CE″,CE′) and/or a bisector (B) of the angle α.