Cutting Insert Groove Geometry for Better Coolant Flow
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Solution Overview
Problem
Existing cutting tool inserts face challenges in effectively supplying coolant to the region near the cutting edge due to groove designs that hinder coolant flow, leading to reduced cooling efficiency and increased friction and wear.
Innovation Solution
The insert features a groove with an angle θ1 of 20-90° relative to the ridgeline and an angle θ2 of 95-135° between the bottom surface and the raised surface, allowing for efficient coolant flow and supply to the cutting edge, while maintaining low friction and wear resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If grooves are formed by disk-shaped grindstone, then grooves can be created on the insert surface, but the bottom surface becomes shallower near the cutting edge causing poor coolant supply
Solution Approach 1:
The patent changes the geometric parameters of the groove, specifically setting the angle θ1 between 20-90 degrees and angle θ2 between 95-135 degrees. These parameter optimizations ensure that the groove maintains sufficient depth near the cutting edge while preventing chip entanglement, thereby improving coolant supply to the cutting edge region.
Solution Approach 2:
The groove design implements local quality by having different cross-sectional characteristics at different positions. The groove depth and angle vary along its length, with the bottom surface being shallower near the cutting edge (first end part) and deeper toward the rear (second end part), optimizing both chip evacuation and coolant delivery to specific regions.
2Ease of manufacture
If grooves are formed by laser beam or electron beam, then grooves can be created on the insert surface, but the wall surface becomes moderately raised hindering coolant flow
Solution Approach 1:
The patent optimizes the groove geometry by controlling the angle θ2 between 95-135 degrees, which prevents excessive raising of the wall surface. This angular parameter control ensures that the groove walls remain relatively flat, facilitating smooth coolant flow toward the cutting edge without significant obstruction from raised surfaces.
3Ease of manufacture
If grooves are formed by drill, then grooves can be created on the insert surface, but the end surface becomes vertically raised hindering coolant flow
Solution Approach 1:
The patent specifies angle θ2 between 95-135 degrees to control the groove geometry, preventing the vertical raising of the end surface that occurs with drill formation. This angular optimization ensures that even when formed by drilling, the groove maintains a profile that allows efficient coolant flow to the cutting edge.
4Productivity
If insert is used for high-speed machining, then productivity is improved, but temperature rise increases requiring effective cooling
Solution Approach 1:
The patent utilizes hydraulic cooling by designing grooves that serve as channels for coolant delivery. The optimized groove geometry (angles θ1 and θ2) ensures effective coolant flow along the insert surface to the cutting edge region, providing active cooling that enables sustained high-speed machining by removing generated heat.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration enhances coolant supply to the cutting edge, reducing friction and wear, enabling high-speed machining with improved cutting tool performance and extended tool life.
Implementation Method 1
The groove is extended from a first end part being an end part closest to the cutting edge to a second end part being an end part most away from the cutting edge. The groove includes an opening and a bottom surface. An angle θ2 formed by the bottom surface and a raised surface extended from the bottom surface toward the first end part is 95-135°.
Data Source
AI summary
An insert includes a base. The base includes first and second surfaces, and a cutting edge on at least a part of a ridgeline of the first and second surfaces. The first surface includes a groove away from the ridgeline and at an angle θ1 of 20-90° relative to the ridgeline. The groove extends from a first end part closest to the cutting edge to a second end part most away from the cutting edge. The groove includes an opening and a bottom surface. An angle θ2 formed by the bottom surface and a raised surface extended from the bottom surface toward the first end part is 95-135°. A cutting tool includes a holder, which has a length extending from a first end to a second end and includes a pocket located on a side of the first end, and the insert located in the pocket.