Cutting Insert Corner Chip Breaker for Groove Machining
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Solution Overview
Problem
Conventional cutting inserts with small tilt angles for chip breakers are ineffective in fragmenting chips during groove machining, especially when finishing the inner surface of pre-formed grooves.
Innovation Solution
A cutting insert with corner wall surfaces having a tilt angle of 40° or larger relative to the boss surface, featuring a two-step protrusion design for efficient chip fragmentation, where the first corner wall surface has a tilt angle of 40° to 90° and the second corner wall surface has a smaller tilt angle, both protruding in a circular arc shape towards the corner cutting edge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the tilt angle of the chip breaker surface is kept small, then resistance during fabrication is reduced, but chip fragmentation is insufficient
Solution Approach 1:
The invention applies different tilt angles to different regions of the chip breaker surface. The first corner wall surface has a tilt angle of 40° to 90° for effective chip fragmentation, while the second corner wall surface has a smaller tilt angle to reduce resistance. This local differentiation allows each region to optimize its function without compromising the other.
Solution Approach 2:
The chip breaker surface is segmented into multiple distinct surfaces with different tilt angles. Specifically, the corner wall surfaces are divided into a first corner wall surface (with larger tilt angle) and a second corner wall surface (with smaller tilt angle), allowing independent optimization of chip fragmentation and resistance reduction functions.
2Reliability
If the tilt angle of the chip breaker surface is increased to improve chip fragmentation, then chip breaking performance is enhanced, but resistance during fabrication increases
Solution Approach 1:
Different regions of the chip breaker are assigned different tilt angles based on their specific functions. The first corner wall surface uses a larger tilt angle (40° to 90°) where chip fragmentation is critical, while the second corner wall surface uses a smaller tilt angle where resistance reduction is more important.
Solution Approach 2:
The chip breaker surface is divided into segmented zones with distinct tilt angles. The first corner wall surface and second corner wall surface are clearly separated, with the first handling chip fragmentation and the second managing resistance, allowing both functions to be optimized simultaneously.
3Ease of manufacture
If a conventional chip breaker design is used, then manufacturing is simple, but chip fragmentation is insufficient when finishing pre-formed grooves
Solution Approach 1:
The invention enhances the conventional chip breaker design by adding local complexity only where needed - the corner wall surfaces with different tilt angles are specifically configured at the corners where chip fragmentation is most critical during groove finishing, while maintaining simpler designs in other areas.
Solution Approach 2:
The chip breaker is segmented into conventional surfaces and enhanced corner surfaces. The corner wall surfaces are divided into first and second surfaces with different tilt angles, providing targeted chip fragmentation capability for groove finishing while maintaining overall design simplicity.
Data Source
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AI summary
A cutting insert capable of performing groove machining while efficiently fragmenting chip is provided. A cutting insert 10 includes a front cutting edge 111, a pair of side cutting edges 113, a pair of corner cutting edges 112 each connecting the front cutting edge and a corresponding one of the side cutting edges, corner rake surfaces 122 extending from the corner cutting edges 112, and a protrusion part 150 protruding from the corner rake surfaces 122 and provided with a flat boss surface 160 at a leading end. Corner wall surfaces 180 extending from the boss surface 160 toward the corner rake surfaces 122 are formed at the protrusion part 150. At least a part of the corner wall surfaces 180 has a tilt angle of 40° or larger relative to the boss surface 160.