Cutting Insert Projections Curve Chips
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Solution Overview
Problem
Conventional cutting inserts struggle to efficiently curve chips during high depth cuts, often resulting in chips being insufficiently curved and excessively long due to the configuration of projections on the cutting insert.
Innovation Solution
A cutting insert with a polygonal columnar shape featuring a convex upper surface, first and second projecting portions, and a unique arrangement of cutting edges, where the second projecting portions are spaced apart from the first projecting portion to form a recess, allowing for effective chip raking and reduction of cutting resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the second projection contacts the first projection at its upper end (as in conventional design), then the chip can move smoothly from the second projection to the first projection, but the chip becomes insufficiently curved and excessively long
Solution Approach 1:
The upper surface is segmented into multiple projecting portions (first, second, third, and fourth projections) with specific spacing relationships. The second and third projections are spaced apart from the first and fourth projections respectively, creating gaps that force the chip to curve more sharply. This segmentation allows the chip to be guided through a more compact path, reducing its final length while maintaining smooth transitions between projection elements.
Solution Approach 2:
The invention introduces vertical spacing between projections at different heights. The second projection is positioned at a different vertical level than the first projection, and similarly the third projection is spaced from the fourth. This dimensional arrangement creates a three-dimensional chip path that forces tighter curving while maintaining operational smoothness.
2Shape
If projections are provided to curve chips, then chip curving capability is improved, but cutting resistance increases and chip ejection becomes difficult
Solution Approach 1:
Different projecting portions are positioned at specific locations on the upper surface with different spacing relationships. The first and second projections are spaced apart to create a specific curving zone, while the third and fourth projections are similarly spaced to create another curving zone. This localized quality variation allows efficient chip curving in specific areas without increasing resistance across the entire cutting surface.
Solution Approach 2:
The invention uses multiple projecting portions rather than a single continuous projection. By providing discrete projections with gaps between them, the chip is subjected to curving action at specific points rather than continuous contact. This partial action reduces the total contact area and cutting resistance while still achieving the desired chip shape through cumulative curving effects at each projection.
Data Source
AI summary
A cutting insert according to one aspect of the present invention includes a polygonal columnar shape, and includes an upper surface, a lower surface and a side surface located between the upper surface and the lower surface, and a cutting edge is formed at an intersecting portion between the upper surface and the side surface, the upper surface includes a main portion of a convex shape including a flat upper end surface, a first projecting portion which projects from the main portion to a corner portion of the upper surface, and a pair of second projecting portions which each project from the first projecting portion to a periphery of the upper surface to interpose a region between a front end of the first projecting portion and the corner portion, and each of upper ends of the pair of second projecting portions is spaced part from the first projecting portion.