Quadrangular Cutting Insert Geometry for Stable Chip Disposal
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Solution Overview
Problem
Existing cutting inserts with quadrangular plate shapes face instability in chip disposal due to narrow rake surfaces, leading to inefficient chip management during milling processes.
Innovation Solution
The cutting insert design features a polygonal shape with inclined surfaces and a through hole for stable fixation, including a first cutting edge on a ridgeline where the first surface intersects with the lateral surface and a second cutting edge on a ridgeline where the lateral surfaces intersect, with specific inclination angles to manage chip flow and disposal efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a quadrangular plate shape cutting insert is used, then the structure is simple and easy to manufacture, but chip disposal stability is poor due to narrow rake surfaces
Solution Approach 1:
The lateral surface is divided into multiple inclined surfaces (first, second, third, fourth inclined surfaces) with different inclination angles, creating segmented zones that guide chips along specific paths. This segmentation allows chips to be directed away from cutting edges through controlled flow paths, resolving the chip disposal stability issue while keeping the overall quadrangular structure simple for manufacturing.
Solution Approach 2:
Different regions of the lateral surface are given different inclination angles tailored to local chip flow requirements. The first and second inclined surfaces have angles optimized for chips from the first cutting edge, while the third and fourth inclined surfaces are optimized for chips from the second cutting edge. This local differentiation improves chip disposal stability without complicating the overall manufacturing process.
2Device complexity
If the rake surface is made narrow to simplify the insert structure, then manufacturing is easier, but chip disposal efficiency deteriorates due to insufficient chip flow control
Solution Approach 1:
The inclined surfaces create dynamic chip flow paths that adapt to chip generation at different cutting edges. Chips generated at the first cutting edge naturally flow along the first and second inclined surfaces, while chips from the second cutting edge follow the third and fourth inclined surfaces. This dynamic guidance system improves chip disposal efficiency without requiring a more complex insert structure.
Solution Approach 2:
Instead of expanding the rake surface area in the traditional plane, the solution uses the inclination angle dimension to create three-dimensional chip flow paths. The multiple inclined surfaces utilize the depth dimension to guide chips away from cutting edges, achieving efficient chip disposal without increasing overall insert complexity.
3Reliability
If multiple inclined surfaces with different angles are introduced to improve chip flow control, then chip disposal stability is improved, but the manufacturing complexity increases
Solution Approach 1:
The lateral surface employs asymmetric inclination angles on different surfaces to optimize chip flow for each cutting edge. The first and second inclined surfaces have angles differentiated from the third and fourth inclined surfaces, creating asymmetric chip paths that prevent chip accumulation. This asymmetric design improves chip disposal stability while maintaining manufacturability through straightforward surface generation methods.
Data Source
AI summary
A cutting insert may include a first surface, a second surface, a first lateral surface, a second lateral surface, a first cutting edge and a second cutting edge. The first lateral surface may include a first inclined surface located along the first cutting edge, a second inclined surface located along the first inclined surface, a third inclined surface located along the second cutting edge, a fourth inclined surface located along the third inclined surface, and a flat surface located along the second inclined surface and the fourth inclined surface. A second inclination angle of the second inclined surface may be smaller than a first inclination angle of the first inclined surface. A fourth inclination angle of the fourth inclined surface may be larger than a third inclination angle of the third inclined surface.