Cutting Insert Groove Design for Chip Control
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Solution Overview
Problem
Cutting inserts with different peripheral cutting edge angles generate chips that flow differently at their boundaries, leading to twisting and difficulties in chip treatment.
Innovation Solution
A cutting insert design featuring a major cutting edge, a flat cutting edge, and a minor cutting edge with a groove part along the major cutting edge, where the rake face and flat part extend continuously from the minor cutting edge to the boundary with the major cutting edge, facilitating chip curling and stabilization for various chip sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cutting edges with different peripheral cutting edge angles are used to reduce damage, then cutting edge durability is improved, but chip flow becomes distorted and chip treatment becomes difficult
Solution Approach 1:
The invention applies different geometric configurations to different regions of the cutting insert. The major cutting edge has a specific peripheral cutting edge angle optimized for primary cutting, while the minor cutting edge has a larger angle optimized for damage reduction. The groove part is strategically positioned along the major cutting edge to specifically address chip flow control in that region, allowing each area to have optimized properties for its specific function.
Solution Approach 2:
The groove part acts as an intermediary element between the major and minor cutting edges. It provides a controlled path for chips generated by the major cutting edge, guiding them through the groove and preventing distortion that would otherwise occur at the boundary region where chips from both cutting edges meet. This intermediary structure mediates the interaction between chips from different cutting edges.
2Productivity
If multiple cutting edges with different angles are used, then cutting performance is improved, but chip discharge performance deteriorates
Solution Approach 1:
The invention segments the chip flow path by introducing the groove part along the major cutting edge. This groove divides the chip discharge region into distinct zones, allowing chips from the major cutting edge to follow a controlled path through the groove, while chips from the minor cutting edge are directed along a different path. This segmentation prevents chip entanglement and improves overall chip discharge performance.
3Manufacturing precision
If the rake face and flat part are made continuous from minor cutting edge to major cutting edge boundary, then small chips are curled effectively, but chip flow stability for large chips may be compromised
Solution Approach 1:
The invention applies different geometric configurations to different regions of the cutting insert. The major cutting edge has a specific peripheral cutting edge angle optimized for primary cutting, while the minor cutting edge has a larger angle optimized for damage reduction. The groove part is strategically positioned along the major cutting edge to specifically address chip flow control in that region, allowing each area to have optimized properties for its specific function.
Data Source
Figure 1
Figure 2(a)~2(b)
Figure 3
AI summary
A cutting insert of the present invention includes an upper surface; a lower surface; a side surface connected to the upper surface and the lower surface; and a cutting edge which is located along an intersection of the upper surface and the side surface, and includes a major cutting edge, a flat cutting edge, and a minor cutting edge located between the major cutting edge and the flat cutting edge. The upper surface includes a flat part located away from the cutting edge and being perpendicular to a central axis of the cutting insert, and a rake face inclined downward from the cutting edge to the flat part. In at least a part between the major cutting edge and the flat part, a groove part lies along the major cutting edge. The groove part includes the rake face and a rising face which is inclined upward from the rake face to the flat part and connects the rake face and the flat part. A connection part where the rake face and the flat part exist continuously extends from the minor cutting edge to a boundary of the minor cutting edge and the major cutting edge. A cutting tool including the cutting insert, and a method of manufacturing a machined product using the cutting tool are also provided.