Cutting Insert Asymmetric Protrusions Chip Discharge
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Solution Overview
Problem
Cutting inserts used in face grooving processes face challenges with lateral chip discharge due to speed differences between cutting edges, leading to spiral chip discharge and compromised chip discharge performance.
Innovation Solution
The cutting insert features a pair of raised parts with protrusions oriented along the perpendicular bisector, where the first protrusion is closer and the second protrusion is higher, to deform and stabilize chip discharge, reducing lateral shift and improving chip balance and discharge efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a cutting insert with helical surfaces is used for face grooving, then chip rounding and division are improved, but lateral chip discharge shift occurs due to cutting speed difference between right and left end sides
Solution Approach 1:
The invention introduces asymmetric protrusions on the rake surface, where the first protrusion is located closer to the cutting edge and the second protrusion is located farther away. This asymmetric arrangement compensates for the cutting speed difference between right and left end sides, stabilizing the chip discharge direction and preventing lateral shift while maintaining effective chip rounding and division.
2Productivity
If the cutting edge has different cutting speeds on right and left end sides, then chip generation occurs, but spiral chip discharge results in deteriorated chip discharge performance
Solution Approach 1:
The invention applies local quality by positioning protrusions at specific locations on the rake surface. The first protrusion is placed closer to the cutting edge to address chip formation at one location, while the second protrusion is placed farther away to address chip discharge stability at another location. This localized structural differentiation stabilizes chip discharge direction and prevents spiral discharge, thereby improving overall chip discharge performance.
3Manufacturing precision
If protrusions are added to the rake surface to stabilize chip discharge, then chip discharge direction is improved, but device complexity increases
Solution Approach 1:
The invention segments the rake surface by introducing distinct first and second protrusions at different positions. This segmentation allows each protrusion to perform a specific function: the first protrusion addresses chip formation and control, while the second protrusion addresses chip discharge stabilization. By dividing the rake surface into functional segments, the invention achieves precise chip discharge control without requiring complex overall structural changes.
Data Source
Figure 1(a)~1(d)
Figure 2
Figure 3
AI summary
A cutting insert according to an embodiment of the present invention includes an upper surface, a side surface, and a first cutting edge located at an intersection of the upper surface and the side surface. The upper surface includes a pair of raised parts located opposite to each other with a perpendicular bisector of the first cutting edge interposed therebetween. A top of each of the pair of raised parts includes at least two protrusions oriented toward a direction along the perpendicular bisector in a top view. Each of the at least two protrusions includes a first protrusion located on a side closest to the perpendicular bisector, and a second protrusion which is located on a side further away from the perpendicular bisector than the first protrusion, and is located at a higher position than the first protrusion. A cutting tool including the cutting insert, and a method of manufacturing a machined product by using the cutting tool are also provided.