Cutting Insert Groove Design for Vibration Reduction
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Solution Overview
Problem
Cutting tools with cutting inserts experience significant vibration and chipping during metal cutting due to high cutting forces, particularly in heavy cutting operations, which compromises cutting performance and tool longevity.
Innovation Solution
The cutting insert design incorporates a combination of flat and tilted cutting edges with strategically placed grooves to reduce stress concentrations and cutting forces, allowing for improved cutting properties and reduced vibration and chipping. The grooves are positioned to minimize the impact of stress at critical cutting edge intersections and are designed to ensure compatibility between strength retention and cutting edge angle maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a cutting insert with flat and tilted cutting edges is used, then cutting force is reduced and cutting performance is improved, but the cutting edge becomes susceptible to stress concentration and chipping at the intersection region
Solution Approach 1:
The patent applies local quality by creating a groove specifically at the intersection region of the flat and tilted cutting edges. This groove is not uniformly distributed but localized at the critical stress concentration point, providing stress relief exactly where needed without compromising the overall strength of the cutting edge structure.
Solution Approach 2:
The cutting edge is segmented into distinct regions: a flat cutting edge portion, a tilted cutting edge portion, and a groove region that separates them. This segmentation allows each portion to perform its specific function while the groove acts as a stress breaker, dividing the continuous cutting edge into functional segments that reduce stress transmission.
2Strength
If the flat cutting edge has the same height as the high-positioned corner cutting edge, then the strength of the cutting edge is retained, but the cutting edge angle compatibility is compromised
Solution Approach 1:
The patent changes the geometric parameters of the cutting edge by introducing a groove that modifies the effective cutting edge angle. The groove creates a localized change in the cutting edge geometry, allowing the flat cutting edge to maintain its height for strength while the groove itself provides the necessary angle variation for optimal cutting performance.
3Reliability
If grooves are added to the cutting edge to reduce stress concentration, then vibration and chipping are reduced, but the device complexity increases
Solution Approach 1:
The patent extracts material from the cutting insert by creating a groove that removes material from the intersection region of the cutting edges. This extraction of material serves to reduce stress concentration and prevent chipping, while the groove design is kept minimal and functional rather than adding complex structural elements.
Data Source
AI summary
An insert comprises an insert main body having an upper surface and a plurality of side surfaces, a cutting edge located between both ends of a ridge which is between at least one side surface among the side surfaces and the upper surface, a high-positioned portion located at one end of the ridge, and a low-positioned portion located lower in the thickness direction of the insert main body than the high-positioned portion and located at the other end of the ridge. The cutting edge comprises a first flat cutting edge having substantially the same height as the high-positioned portion, and a tilted cutting edge having a height decreasing from the high-positioned portion toward the low-positioned portion. On at least the one side surface, at least one groove extends from the side surface to the upper surface to divide the cutting edge by the groove, and at least the one groove is formed at a region including an intersection of a first extension line formed by imaginarily extending the first flat cutting edge with a second extension line formed by imaginarily extending the tilted cutting edge. This enables reduction in the occurrence of vibration during cutting, and the chipping.