Multi-Edge Cutting Insert Geometry for Chip-Safe Adjacent Edges
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Solution Overview
Problem
In cutting inserts, especially double-sided ones, the inclination of major cutting edges upward and to the right often results in chips from one cutting edge damaging adjacent unused edges, reducing cost-effectiveness due to premature damage of unused cutting edges.
Innovation Solution
A cutting insert design with an upper surface and lower surface of the same shape, featuring major cutting edges inclined upward and to the right, combined with a negative radial rake angle and reduced cutting angle, ensures chips are directed away from adjacent edges, maintaining edge usability and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the major cutting edge is inclined upward and to the right to increase the apparent axial inclination angle, then the sharpness of the cutting edge is improved, but chips discharged from the cutting edge will damage the unused cutting edge in the adjacent section
Solution Approach 1:
The cutting insert employs asymmetric geometry where the upper surface is inclined relative to the axial direction, creating different height positions at different radial locations. This asymmetric configuration directs chips away from adjacent unused cutting edges while maintaining the improved sharpness from the upward-inclined major cutting edge.
Solution Approach 2:
The solution introduces a height dimension variation across the upper surface by inclining it relative to the axial direction. This creates a three-dimensional chip discharge path that elevates chips above the level of adjacent cutting edges, preventing contact and damage while preserving the beneficial upward inclination of the major cutting edge.
2Strength
If the upper surface is inclined relative to the axial direction to increase the apparent axial inclination angle, then the cutting sharpness is improved, but the height position of the upper surface increases toward the outer periphery
Solution Approach 1:
The upper surface is designed with varying height positions at different radial locations, creating local quality differences. The height position is controlled to be lower near the attachment hole and increases toward the outer periphery within controlled limits, allowing chip discharge functionality while maintaining overall structural integrity and acceptable geometry.
3Strength
If the major cutting edge extends downward and to the right, then the apparent axial inclination angle is increased, but chips will contact and damage the cutting edge in the right adjacent section
Solution Approach 1:
The upward inclination of the major cutting edge, which initially seemed to cause chip contact issues, is converted into a benefit by combining it with the inclined upper surface. This combination redirects chips upward and away from adjacent cutting edges, transforming what could be a harmful configuration into a beneficial chip evacuation path.
Data Source
AI summary
Provided is a cutting insert in which cutting edges in a plurality of sections can be used, and it is possible to keep chips, which are discharged from a cutting edge in a section that is being used, from damaging an unused cutting edge in an adjacent section. An edge where an upper surface and a peripheral side surface intersect is divided into a plurality of sections AB, BC, CD, and so on. In each of the plurality of section, the section AB, for example, includes one minor cutting edge and one major cutting edge that is longer than the minor cutting edge. The major cutting edge is inclined at an angle α to be away from a lower surface gradually while extending away from the minor cutting edge. A height position of the upper surface in an up-down direction in which the upper surface and the lower surface oppose each other does not change as the upper surface extends toward the attachment hole, or the height position decreases in a direction from the upper surface toward the lower surface.