Cutting Insert Protrusions for Stable Threading Chip Flow
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Solution Overview
Problem
Conventional cutting inserts for threading processes face instability in chip flow direction due to the distance between the cutting edge and the inclined surface, making it difficult to control chip flow effectively.
Innovation Solution
A cutting insert with a polygonal upper surface, side surface, and protrusions, where the second and third protrusions are closer to the corner part than the first protrusion, allowing for stable chip flow control through radial and flank infeed machining methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the inclined surface is located behind the protrusion to provide structural support, then the structural stability is improved, but the distance from the cutting edge to the inclined surface becomes long, causing chip flow direction to become unstable before chips contact the inclined surface
Solution Approach 1:
The single protrusion is divided into multiple protrusions (first protrusion, second protrusion, third protrusion) arranged at different positions and heights. This segmentation allows each protrusion to perform specific functions: the first protrusion provides structural support while the second and third protrusions control chip flow direction, resolving the contradiction between structural stability and chip flow stability.
Solution Approach 2:
The invention introduces a new spatial dimension by arranging protrusions at different heights (vertical dimension) in addition to their horizontal positions. The first protrusion is positioned at a higher level than the second and third protrusions, creating a multi-level structure that simultaneously provides structural support and effective chip flow control without requiring a long distance from the cutting edge.
2Device complexity
If a single protrusion is used on the rake surface, then the device complexity is reduced, but the chip flow control capability is insufficient
Solution Approach 1:
The single protrusion is segmented into multiple protrusions with different positions and heights. The first protrusion is located on the bisector of the corner part, while the second and third protrusions are adjacent to it in a direction orthogonal to the bisector. This segmentation enhances chip flow control capability without excessive complexity increase.
Solution Approach 2:
Different protrusions are given different local qualities through their varying heights and positions. The first protrusion has a greater height than the second and third protrusions, creating localized functional zones: the first protrusion primarily provides structural support while the second and third protrusions specifically control chip flow direction in different areas.
Data Source
AI summary
According to the present disclosure, a cutting insert includes an upper surface having a polygonal shape and includes a corner, a side surface adjacent to the upper surface, a cutting edge and a protrusion. The cutting edge is located at a ridge part in which the upper surface intersects with the side surface and includes a corner part located at the corner. The protrusion is located on the upper surface. The protrusion includes a first protrusion on a bisector of the corner in a top view. The protrusion further includes a second protrusion adjacent to the first protrusion in a direction orthogonal to the bisector. The second protrusion is closer to the corner than the first protrusion in the top view.