Cutting Insert Dual-Face Chip Breaker Design
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Solution Overview
Problem
The existing positive cutting inserts face challenges in designing optimal chip breakers for both the outermost and central regions of a hole, as the limited area on the upper face compromises the design freedom and efficiency of chip breakers for one region, potentially deteriorating the chip discharge efficiency of the other.
Innovation Solution
A plate-like cutting insert with rake faces on both the upper and lower faces, allowing separate formation and optimization of chip breakers for each cutting edge, where the outer cutting edge is on the upper face and the inner cutting edge is on the lower face, enabling independent design and improved chip discharge performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If both chip breakers for outermost region cutting edge and central region cutting edge are formed on the upper face, then the cutting insert can perform both cutting operations, but the design freedom and optimization of each chip breaker is compromised due to limited upper face area
Solution Approach 1:
The invention utilizes both the upper face and lower face of the cutting insert to form chip breakers, effectively adding a dimensional aspect (using the third dimension of the insert body) to resolve the space limitation. The outer cutting edge chip breaker is formed on the upper face while the inner cutting edge chip breaker is formed on the lower face, allowing both chip breakers to be optimized independently without competing for the same surface area.
2Manufacturing precision
If the chip breaker for one cutting edge is optimized, then chip discharge efficiency for that cutting edge is improved, but the design area and depth for the other chip breaker is reduced
Solution Approach 1:
The invention segments the chip breaker formation into two separate locations: the outer cutting edge chip breaker is formed on the upper face while the inner cutting edge chip breaker is formed on the lower face. This segmentation allows each chip breaker to be designed and optimized independently with sufficient area and depth, without one chip breaker encroaching on the design space of the other.
3Device complexity
If a single upper face is used for both chip breakers, then the insert structure is simplified, but chip discharge efficiency of at least one chip breaker deteriorates
Solution Approach 1:
The invention resolves the conflict between structural simplicity and chip discharge efficiency by utilizing the lower face of the insert for the inner cutting edge chip breaker. This dimensional approach maintains relative structural simplicity while ensuring that both chip breakers have adequate space and depth for optimal chip discharge performance.
Data Source
Figure 1
Figure 2
Figure 3A~3C
AI summary
A cutting insert capable of designing an optimal shape for each of a chip breaker for a cutting edge used for cutting of an outermost region of a hole is provided. A substantially polygonal upper face (2), a substantially polygonal lower face (3), and a plurality of side faces (4m, 4s) extending between the upper face (2) and the lower face (3) are provided, wherein the plurality of side faces (4m, 4s) include a main side face (4m) constituting a flank of a linear cutting edge (5b) and a sub side face (4s) constituting a flank of a corner cutting edge (5a), the main side face (4m) has a relief angle of 0°, the sub side face (4s) has a relief angle larger than 0°, and a second cutting edge (8) is further provided at an intersection portion between the main side face (4m) and the lower face (3).