Dual-Stage Cutting Insert for Chip Control Across Variable Feed
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Solution Overview
Problem
Conventional cutting inserts face challenges in chip discharge during high-feed and low-feed machining operations, particularly at high and low depth cuts, with limited adaptability and insufficient chip control in various cutting conditions.
Innovation Solution
A cutting insert design featuring a prismatic cutting edge body with a recessed part for low-depth cutting and a projected part on the substrate for high-depth cutting, allowing adaptive chip control across a wide range of conditions through a dual-stage chip breaker mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a projection for chip control is formed on the rake surface of the cutting tool main body, then chip control is improved for high-depth cutting, but chip control deteriorates for low-depth cutting and low-feed operation
Solution Approach 1:
The chip control function is segmented into two distinct structures: a projection on the substrate for high-depth cutting and a recessed part on the cutting edge body for low-depth cutting. This segmentation allows each structure to specialize in specific cutting conditions, resolving the contradiction between optimizing for high-depth cutting while maintaining adaptability to low-depth cutting and low-feed operation.
Solution Approach 2:
Different regions of the cutting insert are given different geometries tailored to specific cutting conditions. The projection on the substrate has characteristics optimized for high-depth cutting, while the recessed part on the cutting edge body has characteristics optimized for low-depth cutting and low-feed operation. This local differentiation enables the single insert to adapt to various cutting conditions.
2Ease of manufacture
If the sintered body has a flat upper surface, then manufacturing is simplified, but chip control deteriorates during low depth cutting and low-feed operation
Solution Approach 1:
Instead of making the entire upper surface complex, only a local recessed part is formed on the cutting edge body at the position where low-depth cutting chip control is needed. This localized modification maintains manufacturing simplicity for the majority of the structure while providing enhanced chip control specifically where required.
3Manufacturing precision
If a recessed shape is provided on the upper surface of the sintered body, then chip control is improved for low depth cutting, but chip control deteriorates for high depth cutting and high-feed operation
Solution Approach 1:
The chip control function is divided between two structures: the recessed part on the cutting edge body handles low-depth cutting, while the projection on the substrate handles high-depth cutting and high-feed operation. This segmentation resolves the contradiction by ensuring each structure addresses specific cutting conditions without compromising overall adaptability.
4Manufacturing precision
If the cutting insert is designed for high-depth cutting, then chip control is improved for high depth of cut, but adaptability to low depth cutting and low-feed operation deteriorates
Solution Approach 1:
The cutting insert is designed with multi-functional chip control structures that enable it to perform effectively across a wide range of cutting conditions. The projection on the substrate serves high-depth cutting while the recessed part on the cutting edge body serves low-depth cutting and low-feed operation, making the single insert universal for various machining operations including rough machining, profile machining, and finishing.
Data Source
AI summary
Chip discharge during high-feed machining and low-feed machining particularly in a high-depth-of-cut state or the like is improved so as to provide adaptability to a wide range of cutting conditions during low depth and high depth cutting and during low-feed and high-feed machining and allow so-called freedom of feed during cutting to be improved. A cutting insert includes a cutting edge body and a substrate to which the cutting edge body is joined. The cutting edge body has a prismatic shape having a longitudinal direction and a lateral direction perpendicular to the longitudinal direction and includes a cutting edge formed on an intersecting edge between a peripheral side surface and an upper surface of the cutting edge body having the prismatic shape and a recessed part formed at a position on the upper surface of the cutting edge body which is more distant from the intersecting edge than from the cutting edge. The substrate has a projected part upwardly projecting from the upper surface of the cutting edge body.