Cutting Insert Curved Relief Face Chipping Resistance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing cutting inserts for face milling cutters are prone to chipping, which reduces their durability and lifespan, affecting processing efficiency.
Innovation Solution
A cutting insert design featuring a rake face, peripheral side surface with a positive relief angle, and strategically formed cutting edges, including a major, minor, and intermediate cutting edge, with a curved relief face and chamfered corners, optimized to distribute cutting loads and reduce chipping risk.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a positive relief angle is formed on the cutting insert, then chip removal capability is improved, but the cutting edges become more prone to chipping
Solution Approach 1:
The relief face is divided into multiple segments: a major relief face with a first relief angle, a minor relief face with a second relief angle, and an intermediate relief face connecting them. This segmentation allows different portions of the cutting edge to have different relief angles optimized for their specific functions, resolving the contradiction between chip removal and chipping resistance.
Solution Approach 2:
Different relief angles are applied to different locations on the relief face. The major relief face has a larger relief angle for effective chip removal, while the minor relief face has a smaller relief angle to protect the cutting edge from chipping. The intermediate relief face provides a smooth transition between these two regions.
2Productivity
If the cutting edge is made sharper for better cutting performance, then material removal efficiency increases, but the cutting edge becomes more susceptible to chipping
Solution Approach 1:
The cutting edge is designed with varying relief angles along its length. The portion associated with the major relief face has a larger relief angle for efficient material removal, while the portion associated with the minor relief face has a smaller relief angle to maintain edge strength and prevent chipping.
Solution Approach 2:
The cutting edge is effectively segmented into different functional zones corresponding to the major and minor relief faces, allowing each zone to be optimized for its specific role in the cutting process.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The present invention provides an insert (10) for removal installation in a tool body. The insert (10) includes a cutting edge (22) formed at an intersection of a rake face (18) formed on a first surface (12) and a relief face (20) with a positive relief angle. The relief face (20) includes a major relief face (20a) located adjacent to a major cutting edge (22a), a first minor relief face (20b) located adjacent to the first minor cutting edge (22b), and an intermediate relief face (20m) located adjacent to the intermediate cutting edge (22m) and extending between the major relief face and the first minor relief face. The intermediate relief face includes a protruding curved relief face (20d) extending from the first surface (12). An intersection of the curved relief face (20d) and the rake face (18) has a predetermined radius of curvature and has substantially the same shape as that of an intersection of the curved relief face (20d) and a second surface (14).