Cutting Insert Ridge Structure for Stable Chip Flow Across Feed Rates
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Solution Overview
Problem
Conventional cutting inserts experience unstable chip disposal during both low and high feed machining due to chips not consistently contacting the ridges, leading to instability in chip flow and the need for different inserts based on machining conditions.
Innovation Solution
A cutting insert with a quadrilateral upper and lower surface configuration, featuring double-sided cutting edges and specific protrusions and projections that ensure consistent chip contact at varying feed rates, allowing for stable chip flow across both low and high feed machining conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a cutting insert with a single ridge configuration is used, then chip contact is achieved during low feed machining, but chip flow stability deteriorates during high feed machining
Solution Approach 1:
The cutting insert divides the chip flow control function into multiple independent elements: a first ridge for initial chip contact and curvature, and a second ridge for additional chip control. This segmentation allows each ridge to perform its specific function independently, ensuring stable chip disposal across different feed rates without requiring a single complex structure to handle all conditions.
Solution Approach 2:
The cutting insert design integrates multiple ridges that collectively serve the universal function of chip flow control across varying machining conditions. The first ridge handles low feed machining by curving chips, while the second ridge provides additional control during high feed machining, making the insert universally applicable to both low and high feed rate operations without requiring replacement.
2Speed
If chips flow horizontally from the cutting edge during high feed machining, then cutting speed is maintained, but chip contact with ridges is lost leading to unstable chip flow
Solution Approach 1:
The invention addresses the horizontal chip flow issue by introducing a vertical dimension to chip control through the second ridge. When chips rise horizontally during high feed machining, the second ridge positioned at a different vertical level intercepts and redirects the chips back onto the upper surface, creating a three-dimensional chip control path that maintains stability regardless of feed rate-induced horizontal flow tendencies.
Data Source
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AI summary
A cutting insert according to an embodiment has an upper surface, a lower surface and a side surface, and a polygonal plate shaped in which a cutting edge is formed at a ridgeline where the upper surface and the side surface intersect each other. The upper surface has a major part having a flat upper end surface, a first protrusion protruding from the major part toward a corner part of the upper surface, a second protrusion protruding from the first protrusion toward the corner part, and a pair of projections located between the second protrusion and the cutting edge. A height of an upper end of the first protrusion from the lower surface is lower than a height of the upper end surface of the major part and is higher than a height of the cutting edge. A height of an upper end of the second protrusion from the lower surface is equal to the height of the cutting edge. A height of an upper end of each of the pair of projections is lower than the height of the second protrusion.