Cutting Insert Protruded Parts Chip Discharge
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Solution Overview
Problem
Existing cutting inserts face challenges in efficiently discharging chips due to wide protruded parts near the cutting edge, leading to increased cutting resistance and poor chip discharge performance.
Innovation Solution
A cutting insert design with a rake surface inclined inward at a specific angle and protruded parts having a larger width inwardly, where the inclination angles of the rake surface and protruded parts satisfy a particular relationship, enhancing chip discharge and reducing cutting resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the protruded part has a relatively large width in the vicinity of the cutting edge, then the connection between recessed parts is strengthened, but the cutting resistance increases and chip discharge becomes difficult
Solution Approach 1:
The patent applies local quality by varying the width of the protruded part along its length. The protruded part has a larger width at the inner end (away from cutting edge) and a smaller width at the outer end (near cutting edge), creating different local properties: strong connection at the inner end and reduced cutting resistance at the outer end where it contacts the workpiece.
2Device complexity
If the recessed parts and protrusion are smoothly continuous, then the structure is simplified, but chip discharge performance deteriorates
Solution Approach 1:
The patent applies segmentation by dividing the cutting insert top surface into distinct recessed parts and protruded parts. This segmentation creates discrete chip discharge paths through the recessed parts while maintaining structural integrity through the protruded parts, improving chip evacuation without excessive complexity.
Data Source
Figure 1(a)~1(c)
Figure 2(a)~2(b)
Figure 3(a)~3(b)
AI summary
A cutting insert according to an embodiment of the present invention includes an insert body including an upper surface, a lower surface, a side surface connected to each of the upper surface and the lower surface, and a cutting edge located at an intersection of the upper surface and the side surface. The insert body is divided into a cutting section and a fixing section. A region of the upper surface located at the cutting section includes a rake surface which is located further inward than the cutting edge and is inclined as going inward at an inclination angle α1 with respect to a reference plane perpendicular to a central axis, and a plurality of protruded parts arranged along the cutting edge. Each of the plurality of protruded parts includes a first surface which is inclined as going inward at an inclination angle α4a with respect to the reference plane and has a larger width as going inward in a top view. The inclination angles α1 and α4a satisfy a relationship of α1>α4a. A cutting tool with the cutting insert, and a method of manufacturing a machined product by using the cutting tool are also provided.