Cutting Insert Dual Rake Face Chip Control
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Solution Overview
Problem
Existing cutting inserts generate thick chips, leading to increased heat and wear on the cutting edges, resulting in reduced tool life due to the small rake angle along cutting edges and the likelihood of chips colliding with the rake face, causing further wear.
Innovation Solution
A cutting insert with a rake face featuring two distinct rake angles, where the first rake face has a smaller angle for effective cutting and the second rake face has a larger angle to reduce chip thickness and prevent chip contact, combined with a chip breaker design that promotes chip curling and deformation, thereby reducing heat generation and wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a small rake angle is used along cutting edges, then effective cutting is achieved, but thick chips are generated leading to increased heat and wear
Solution Approach 1:
The rake face is divided into two distinct regions: a first rake face with a smaller rake angle for effective cutting, and a second rake face with a larger rake angle for chip thinning. This segmentation allows each region to perform its specific function optimally, resolving the contradiction between cutting efficiency and chip temperature control.
Solution Approach 2:
Different rake angles are applied to different locations on the rake face. The first rake face (near the cutting edge) has a smaller angle for effective cutting, while the second rake face (further from the cutting edge) has a larger angle for chip thinning. This local differentiation addresses the contradiction by providing location-specific functionality.
2Productivity
If a small rake angle is used along cutting edges, then effective cutting is achieved, but the cutting insert wears away faster reducing tool life
Solution Approach 1:
The rake face is segmented into two functional zones with different rake angles. The first rake face maintains smaller angles for effective cutting, while the second rake face provides larger angles to thin chips before they contact the breaker wall, reducing wear and extending tool life.
Solution Approach 2:
The rake face exhibits local quality variations with different rake angles in different regions. This local differentiation allows the cutting insert to maintain both cutting efficiency and reduced wear through location-specific rake angle optimization.
3Productivity
If chips are thick, then they collide against the breaker wall surface, but this causes increased wear on the rake face
Solution Approach 1:
The second rake face with a larger rake angle performs preliminary chip thinning before the chips reach the breaker wall surface. This preliminary action reduces chip thickness, preventing excessive collision and wear on the rake face while maintaining effective chip breaking.
Data Source
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AI summary
The present invention relates to a cutting insert with a cutting edge. The cutting insert includes a rake face (24) extending along a cutting edge (22a, 22b) and a rising wall surface (32a) extending so as to form a recess (34) along the cutting edge (22a, 22b) together with the rake face (24). The rake face (24) is formed to have a positive rake angle, and includes a first rake face (24a) and a second rake face (24b) arranged in order in a direction in which a distance from the cutting edge (22a, 22b) increases. The second rake face (24b) is larger than the first rake face (24a) in rake angle.