Cutting Insert Protrusion Layout for Chip Flow and Stable Mounting
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Solution Overview
Problem
In high feeding processing or high cutting operations with indexable cutting tools, the chip discharging property is compromised, leading to chips being caught between cutting edges and tool components, potentially causing edge fractures and instability in tool mounting.
Innovation Solution
A cutting insert with a polygonal plate-shaped insert main body featuring two polygonal surfaces, a side surface with a flank face, and a cutting edge. The insert includes protrusions around the mounting hole opening, which act as chip breakers to control chip flow without compromising mounting stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a chip breaker is formed on the rake face to control chip outflow direction, then chip discharging property is improved, but the area of close attachment between boss surface and bottom surface of insert mounting seat becomes small, impairing mounting stability
Solution Approach 1:
The chip breaker is divided into multiple protrusions arranged at intervals around the mounting hole opening, rather than a continuous chip breaker structure. This segmentation allows chip flow control while preserving sufficient boss surface area for stable mounting.
Solution Approach 2:
The protrusions are strategically positioned in the inner periphery side region of the major cutting edge, concentrating chip breaking function in specific locations where chips are most likely to accumulate, while leaving other areas of the boss surface available for mounting contact.
2Adaptability or versatility
If the insert main body is made front-back inversion symmetrical to allow reuse after rotation, then adaptability is improved, but the boss surface area for mounting becomes limited when chip breakers are added
Solution Approach 1:
The chip breaker is segmented into multiple protrusions distributed around the mounting hole, allowing the symmetrical insert design to be maintained while providing effective chip control in multiple directions for both sides of the insert.
Solution Approach 2:
The protrusions serve dual functions: controlling chip outflow during cutting operations and maintaining adequate boss surface area for reliable mounting. The same structural elements achieve both chip management and mounting stability.
Data Source
Figure 1
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Figure 4~5
AI summary
What is presented is a cutting insert including a polygonal plate-shaped insert main body (11) that includes: two polygonal surfaces (12); a side surface (13); and a cutting edge (15), the insert main body (11) has a mounting hole (16) that is centered on an insert center line (L) passing through centers of the two polygonal surfaces (12), the cutting edge (15) includes a major cutting edge (15b) extending from a first end of a corner edge (15a) located at a corner of the polygonal surface (12), and, in the opening of the mounting hole (16), a plurality of protrusions (18) protruding with respect to a boss surface (12a) around an opening of the mounting hole (16) are formed at intervals in a peripheral direction in an inner periphery side region of the major cutting edge (15b).