Cutting Insert Chip-Splitting Lip for Controlled Chip Evacuation
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Solution Overview
Problem
Current machining tools face challenges in producing small, manageable chips with controlled formation, leading to issues such as chip jamming, increased power consumption, and tool wear due to asymmetrical cutting edge segments and stress concentrations caused by conventional chip breakers.
Innovation Solution
The introduction of a cutting insert with a cutting lip featuring a chip cutting edge that extends perpendicularly from the main cutting edge, splitting chips into smaller, more manageable pieces and optimizing each cutting edge segment's geometry for balanced force distribution and improved chip evacuation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conventional chip breakers with notches are used in cutting edges, then chip width is reduced, but stress concentrations and heat concentrations increase at the vertices of the notches
Solution Approach 1:
The cutting edge is divided into multiple segments separated by gaps, with each segment having its own chip breaker. This segmentation distributes the chip breaking function across multiple locations, reducing stress concentration at any single point while maintaining effective chip width control.
Solution Approach 2:
Different portions of the cutting edge are given different properties - some areas have chip breakers for chip control, while gap areas provide relief from stress concentration. The asymmetric positioning of chip breakers on different segments allows localized optimization of chip breaking without uniform stress distribution.
2Shape
If asymmetrical chip breakers are positioned on cutting edge segments, then chip formation is controlled, but cutting forces become unbalanced and local stresses increase
Solution Approach 1:
Chip breakers are intentionally positioned asymmetrically on different cutting edge segments, with varying distances from the centerline. This asymmetric arrangement creates deliberate imbalances in chip formation control that are compensated by the overall symmetric design of having multiple segments, allowing effective chip control while distributing cutting forces more evenly across segments.
3Shape
If multiple chip breakers are used to control chip formation, then chip size is reduced, but the complexity of the cutting edge geometry increases
Solution Approach 1:
The cutting edge is divided into discrete segments with gaps between them, allowing each segment to have simplified chip breaker geometry. This segmentation approach controls chip size through the distribution of multiple simple chip breakers rather than one complex continuous chip breaker, reducing overall geometric complexity while maintaining effective chip control.
4Productivity
If conventional spade cutting inserts are used, then economical hole production is achieved, but chip evacuation becomes difficult with larger chips
Solution Approach 1:
The cutting edge is segmented into multiple sections with gaps between them, and each segment is equipped with its own chip breaker. This segmentation creates multiple chip breaking points along the cutting edge, producing smaller chips that can be more easily evacuated from the hole while maintaining the economical production benefits of spade cutting inserts.
Data Source
AI summary
There is provided a machining assembly and cutting insert for machining metal or like workpieces, wherein the cutting insert body has a cutting end. The cutting end comprises at least one cutting edge and at least one cutting lip formed adjacent the at least one cutting edge. The at least one cutting lip includes at least one cutting protrusion and associated chip cutting edge to split the chip formed by the at least one cutting edge, for producing chips during machining which are of a width that is sufficiently reduced to allow proper evacuation or removal.