Cutting Insert Rake Surface Geometry for Chip Discharge
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Cutting inserts face challenges in chip dischargeability and cutting resistance, especially under large depth of cut conditions, where chips may clog on the rake surface and increase cutting resistance, limiting the allowable depth of cut.
Innovation Solution
A cutting insert design featuring a polygonal top surface, a through-hole, a projecting portion, and a rake surface with specific geometric configurations that enhance chip dischargeability, including a rake surface extending between the cutting edge and the projecting portion, with boundary lines closer to the through-hole side, optimizing chip flow and reducing cutting resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the breaker projecting portion is made high to improve chip curling, then chip curling is enhanced, but chip dischargeability deteriorates and cutting resistance increases under large depth of cut conditions
Solution Approach 1:
The invention transitions from a conventional low breaker design to a high breaker projecting portion that extends significantly from the top surface. This dimensional change in the breaker height creates a new spatial configuration where the breaker can effectively curl chips while the extended rake surface provides a longer chip flow path, resolving the contradiction between chip curling stability and chip dischargeability.
Solution Approach 2:
The invention divides the chip flow path into distinct segments: the initial curling zone at the breaker and the subsequent flow zone along the extended rake surface. This segmentation allows the breaker to focus on curling chips while the extended rake surface handles chip discharge, preventing clogging and reducing cutting resistance under large depth of cut conditions.
2Ease of operation
If the rake surface is extended to improve chip flow, then chip dischargeability is enhanced, but the allowable depth of cut is limited due to chip clogging
Solution Approach 1:
The invention extends the rake surface in the direction from the corner section toward the through-hole, creating an extended chip flow path. This dimensional extension allows chips to flow smoothly over a longer distance, enhancing chip dischargeability while accommodating larger depths of cut without clogging.
Solution Approach 2:
The extended rake surface prepares the chip flow path in advance by providing a longer, smoother trajectory for chip evacuation. This preliminary configuration of the chip flow path ensures that chips can be discharged efficiently even under large depth of cut conditions, increasing the allowable depth of cut.
3Stability of the object's composition
If the breaker projecting portion is made high to improve chip curling, then chip curling is enhanced, but chip dischargeability deteriorates due to clogging on the rake surface
Solution Approach 1:
The invention segments the chip processing function into two distinct zones: the high breaker projecting portion for chip curling and the extended rake surface for chip flow and discharge. This segmentation allows each component to specialize in its function, with the breaker creating stable curls and the extended rake surface providing a clear path for chip evacuation, preventing clogging.
Solution Approach 2:
The invention uses dimensional extension of the rake surface to create additional space for chip flow. By extending the rake surface from the corner section toward the through-hole, the invention provides a longer chip flow path that accommodates the chips curled by the high breaker, ensuring smooth discharge without clogging.
Data Source
AI summary
The cutting insert is provided with: a top surface, a bottom surface, a side surface, a cutting edge located at the intersection portion of the top surface and the side surface; a through hole located from the top surface to the bottom surface; a projecting portion extending from a corner section to a through hole side; and a rake surface located between the cutting edge and the projecting portion. A boundary line between the rake surface and the projecting portion comprises a first end. In a top view, a bisector of the corner section intersects the cutting edge at a first point and intersects a top edge section of the through-hole at a second point. The first end is located closer to the through-hole side than a perpendicular line that passes through a midpoint of a line segment connecting the first point and the second point.