Cutting Insert With Positive Axial Rake Angle
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Solution Overview
Problem
Conventional cutting inserts experience high cutting resistance and poor cutting performance due to negative axial rake angles, leading to limited depth of cut and surface deformation, especially when the depth of cut exceeds 0.5mm, resulting in burrs and reduced precision.
Innovation Solution
A cutting insert design with a positive axial rake angle and reduced radius of curvature for the auxiliary cutting edge, featuring a main cutting edge that extends from adjacent auxiliary cutting edges with a 8° to 18° angle and a convex curve radius of 20mm to 60mm, allowing for increased depth of cut and reduced friction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a negative axial rake angle is used to maintain a relief angle of 4° to 6°, then the side surface of the cutting insert maintains proper clearance from the workpiece, but the cutting resistance increases significantly and cutting performance deteriorates
Solution Approach 1:
The patent changes the axial rake angle parameter from negative (conventional) to positive (invention), specifically setting it to +5°. This parameter change simultaneously reduces cutting resistance while maintaining the necessary relief angle through the geometric configuration of the cutting edges, resolving the contradiction between reliability and cutting force
2Productivity
If the depth of cut is increased beyond 0.5mm, then more material is removed per pass improving productivity, but burrs are produced and surface deformation occurs
Solution Approach 1:
The patent changes the axial rake angle from negative to positive (+5°), which fundamentally alters the chip formation mechanism. This allows deeper cuts (beyond 0.5mm) to be made without producing burrs or causing surface deformation, as the positive rake angle reduces cutting resistance and improves chip flow, thereby resolving the contradiction between productivity and surface quality
3Manufacturing precision
If a large radius of curvature (100mm to 200mm) is used for the auxiliary cutting edge, then the processed surface flatness is improved, but the friction force on the workpiece increases
Solution Approach 1:
The patent reduces the radius of curvature of the auxiliary cutting edge from the conventional 100mm to 200mm range to a smaller value (specifically 20mm to 60mm). This parameter change reduces the friction force between the auxiliary cutting edge and the workpiece while still maintaining adequate surface flatness through the optimized geometric configuration, resolving the contradiction between manufacturing precision and cutting force
Data Source
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AI summary
A cutting insert of the present invention has a body, auxiliary cutting edges of a convex curve shape and main cutting edges. The body has a top surface, a bottom surface, side surfaces connecting the top and bottom surfaces, and corner surfaces connecting the adjacent side surfaces. The auxiliary cutting edges are formed at intersections between the top and bottom surfaces and the side surfaces. The main cutting edges are formed at intersections between the top and bottom surfaces and the corner surfaces. The main cutting edge in the top surface extends from an end of an adjacent auxiliary cutting edge to its center in a direction toward the bottom surface and from the center to an end of another adjacent auxiliary cutting edge in a direction away from the bottom surface.