Cutting Insert Geometry for Controlled Chip Curl in Milling
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Solution Overview
Problem
In cutting processes, particularly in milling operations, chips generated by cutting edges often flow towards the cutting tool, leading to damage of the machined surface, chip wind-up, and clogging, which complicates chip discharge and affects the stability of the cutting process.
Innovation Solution
The cutting insert design features inclined surfaces and rake surfaces that control chip flow direction, with varying widths and curvatures to curl and divert chips away from the cutting tool, reducing the likelihood of chip clogging and enhancing discharge efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If conventional cutting edges are used in milling operations, then cutting capability is maintained, but chips flow towards the cutting tool causing surface damage, chip wind-up, and clogging
Solution Approach 1:
The patent applies local quality by creating different surface geometries at different locations on the cutting insert. The first and second inclined surfaces are positioned at specific locations relative to the cutting edge, with each surface having distinct width characteristics (first inclined surface width increases toward second side, second inclined surface width increases toward first side). This localized geometric variation controls chip flow direction at different regions, effectively diverting chips away from the cutting tool while maintaining cutting effectiveness.
Solution Approach 2:
The patent utilizes curvature principles by designing inclined surfaces with varying widths that create curved chip flow paths. The first inclined surface has a width that becomes larger as approaching the second side, while the second inclined surface has a width that becomes larger as approaching the first side. These curved geometric features guide chips along controlled trajectories, preventing straight-line flow toward the cutting tool and reducing chip clogging.
2Ease of operation
If chip flow is not controlled, then cutting operation is simple, but chips cause surface damage and clogging complicating discharge
Solution Approach 1:
The cutting insert incorporates locally varied surface geometries with the first inclined surface positioned along the first side and the second inclined surface positioned along the second side. Each inclined surface has specific width characteristics that control chip flow in its respective region. This localized geometric design actively manages chip discharge paths, preventing chips from flowing toward the cutting tool and reducing the complexity of chip removal operations.
3Object-affected harmful factors
If inclined surfaces with varying widths are introduced, then chip flow control is improved, but manufacturing complexity increases
Solution Approach 1:
The patent implements local quality through the first and second inclined surfaces with specific width variations. The first inclined surface has a width that becomes larger as approaching the second side, while the second inclined surface has a width that becomes larger as approaching the first side. These localized geometric features provide effective chip flow control by directing chips away from the cutting tool, while the modular surface design allows for relatively straightforward manufacturing processes.
Data Source
AI summary
A cutting insert may include a first surface having a polygonal shape, a second surface, a third surface and a cutting edge. The first surface may include a first corner, a first side, a first inclined surface located along the first side, and a second inclined surface located along the second side. In a plan view of the first surface, a width of the first inclined surface in a direction orthogonal to the first side may become larger as approaching the second side. A width of the second inclined surface in a direction orthogonal to the second side may become larger as approaching the first side.