Cutting Insert Convex Portion for Chip Control
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Solution Overview
Problem
Conventional cutting tools with ultrahigh-pressure sintered compacts face challenges in enhancing chip treatability, particularly in profiling machining where the direction of chip flow changes frequently.
Innovation Solution
A cutting insert with a convex portion protruding between breaker wall surfaces at the corner portion, promoting chip curl and treatability, and featuring a sintered compact with materials like diamond and cubic boron nitride, along with a two-stage chip breaker structure for improved chip control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional breaker wall surfaces are used in ultrahigh-pressure sintered compact cutting tools, then the basic cutting performance is maintained, but chip treatability deteriorates in profiling machining where chip flow direction changes frequently
Solution Approach 1:
The chip breaker structure is segmented into multiple functional zones: conventional breaker wall surfaces for basic chip control, and newly added convex portions with different curvature radii positioned at specific locations. Each segment handles different aspects of chip flow control, with the convex portions specifically addressing changing chip flow directions in profiling machining operations.
Solution Approach 2:
Different regions of the chip breaker are given different geometric properties. The convex portions have specific curvature radii (first curvature radius R1 and second curvature radius R2) that differ from the breaker wall surfaces. This local differentiation allows the chip breaker to apply varying forces to chips depending on their position and flow direction, improving adaptability to profiling machining conditions.
2Ease of operation
If the cutting tool structure is simplified without additional features, then manufacturing is easier, but chip control capability in complex cutting operations is insufficient
Solution Approach 1:
Rather than redesigning the entire chip breaker, the invention adds localized convex portions with specific geometric characteristics (curvature radii R1 and R2) at predetermined positions. This localized modification approach improves chip control capability without substantially increasing overall structural complexity, maintaining ease of manufacture while enhancing performance.
Solution Approach 2:
The convex portions are pre-positioned and pre-shaped with specific curvature radii during manufacturing. This preliminary configuration ensures that when chips encounter these convex portions during profiling machining, the appropriate forces are automatically applied without requiring real-time adjustment, simplifying the overall system while improving chip control.
Data Source
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AI summary
A cutting tool (1) in the present invention includes a cutting edge member (3). The cutting edge member (3) forms a corner portion (2). The cutting edge member (3) includes a cutting edge (7) formed at the intersection of a rake surface (8) and a flank (9), at least two breaker wall surfaces (5) and at least one convex portion (6). The cutting edge (7) includes a first cutting edge (7b) and a second cutting edge (7a) connected thereto. The second cutting edge (7a) is situated at the corner portion (2). Each breaker wall surface (5) is formed to extend along the cutting edge. The convex portion (6) is formed between the two breaker wall surfaces (5) spaced from each other to protrude relatively toward the cutting edge side. A part of the convex portion (6) is situated around a connecting portion of the first and second cutting edges.