Cutting Insert Minor Edge Land Inclination
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Solution Overview
Problem
Conventional cutting inserts experience increased thrust force on minor cutting edges, leading to vibration and poor surface finish quality, and struggle to adapt to various cutting conditions from general to high feed rates.
Innovation Solution
The cutting insert design features a minor cutting edge land portion with a larger peripheral cutting edge angle than the major cutting edge, inclined downward to reduce cutting resistance, and varying land portion widths and angles to balance strength and performance, allowing for effective cutting across different feed rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a minor cutting edge with a larger peripheral cutting edge angle is formed between the major cutting edge and the flat cutting edge, then damage reduction of the cutting edge is improved, but the thrust force on the minor cutting edge increases causing vibration and deterioration of finished surface quality
Solution Approach 1:
The invention applies different land portion widths and inclination angles to different regions of the minor cutting edge. The first land portion has a larger width and smaller inclination angle to provide strength, while the second land portion has a smaller width and larger inclination angle to reduce cutting resistance. This local differentiation allows the minor cutting edge to simultaneously achieve durability and reduced vibration.
2Object-affected harmful factors
If the minor cutting edge land portion is inclined downward toward the central part to reduce cutting resistance, then the thrust force is decreased and vibration is reduced, but the strength of the minor cutting edge may be compromised
Solution Approach 1:
The minor cutting edge land portion is divided into two distinct segments: a first land portion with larger width and smaller inclination angle for strength, and a second land portion with smaller width and larger inclination angle for reducing cutting resistance. This segmentation allows each portion to fulfill its specific function without compromising the other.
3Strength
If the width at the end portion close to the major cutting edge land portion is increased to enhance strength, then the cutting resistance may increase, but if decreased, the strength is compromised
Solution Approach 1:
The invention applies different land portion widths and inclination angles to different regions of the minor cutting edge. The first land portion has a larger width and smaller inclination angle to provide strength, while the second land portion has a smaller width and larger inclination angle to reduce cutting resistance. This local differentiation allows the minor cutting edge to simultaneously achieve durability and reduced vibration.
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; a cutting edge which is located along an intersection of the upper surface and the side surface, and comprises a major cutting edge, a flat cutting edge, and a minor cutting edge located between the major cutting edge and the flat cutting edge; and a land part located along the cutting edge on the upper surface. The land part includes a minor cutting edge land portion located correspondingly to the minor cutting edge. The minor cutting edge land portion is inclined downward toward a central part of the upper surface. The present invention also provides a cutting tool including the cutting insert, and a method of manufacturing a machined product by using the cutting tool.