Cutting Insert Projections for Chip Curving and Packing

Solution Overview

Problem

Conventional cutting inserts fail to effectively manage chip curvature at varying depths of cut and feed rates, leading to reduced durability and increased risk of chip packing due to the need for large second projection inclinations at high feed rates.

Innovation Solution

A cutting insert with a polygonal plate shape featuring a convex main part, first and second projections, and third projections that adjust chip contact based on depth of cut and feed rate, utilizing inclined and planar surfaces to stabilize chip deformation and discharge.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If the inclination of the second projections is increased to facilitate chip curving at high feed rates, then chip curving capability is improved, but the durability of the second projections deteriorates and chip packing is apt to occur

Engineering Contradiction:

Improvechip curving capabilityVSAvoiddurability of second projections

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent applies local quality by differentiating the surface characteristics of different projections. The first projections have inclined surfaces that are curved in a concave shape optimized for chip curving, while the second projection has a planar inclined surface in the portion on the bisector of the corner part. This localized differentiation allows each projection to perform its specific function optimally without compromising the overall system reliability.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent implements dynamics by making the chip curving process adaptable to varying machining conditions. The combination of curved inclined surfaces on first projections and planar inclined surface on the second projection creates a dynamic chip flow path that automatically adjusts to different feed rates and depths of cut, maintaining effective chip curving across a wide range of operating parameters while preventing chip packing.

Inventive Principle:

Principle #15Dynamics

2Adaptability or versatility

If the inclination of the second projections is increased to handle high feed rates, then adaptability to high feed rates is improved, but chip packing is apt to occur

Engineering Contradiction:

Improveadaptability to high feed ratesVSAvoidchip packing

Core Design Contradiction:

Adaptability or versatilityVSObject-generated harmful factors

Solution Approach 1:

The patent applies local quality by differentiating the surface characteristics of different projections. The first projections have inclined surfaces that are curved in a concave shape optimized for chip curving, while the second projection has a planar inclined surface in the portion on the bisector of the corner part. This localized differentiation allows each projection to perform its specific function optimally without compromising the overall system reliability.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent implements dynamics by making the chip curving process adaptable to varying machining conditions. The combination of curved inclined surfaces on first projections and planar inclined surface on the second projection creates a dynamic chip flow path that automatically adjusts to different feed rates and depths of cut, maintaining effective chip curving across a wide range of operating parameters while preventing chip packing.

Inventive Principle:

Principle #15Dynamics

3Ease of operation

If the inclination of the second projections is increased to facilitate chip curving at high feed rates, then ease of chip curving is improved, but the second projections become more susceptible to damage

Engineering Contradiction:

Improveease of chip curvingVSAvoidstrength of second projections

Core Design Contradiction:

Ease of operationVSStrength

Solution Approach 1:

The patent applies local quality by differentiating the surface characteristics of different projections. The first projections have inclined surfaces that are curved in a concave shape optimized for chip curving, while the second projection has a planar inclined surface in the portion on the bisector of the corner part. This localized differentiation allows each projection to perform its specific function optimally without compromising the overall system reliability.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS9393626B2Cutting insert, cutting tool, and method of manufacturing machined product

Publication Date: 2016.07.19 KYOCERA CORP

AI summary

A cutting insert has a polygonal columnar shape and includes an upper surface, a lower surface, a side surface located between the upper surface and the lower surface, and a cutting edge formed at an intersection of the upper surface and the side surface. The upper surface includes a convex-shaped main part including a flat upper end surface, a first projection projecting from the main part to a corner part of the upper surface, a second projection projecting from the first projection toward the corner part, and a pair of third projections respectively projecting from the first projection toward a periphery of the upper surface that interpose at least a part of the second projection between the pair of third projections. A surface of the first projection is an inclined surface curved in a concave shape, and a surface of the second projection is a planar inclined surface.