Cutting Insert Rake Surface for Ductile Material Chip Discharge
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Solution Overview
Problem
Conventional cutting inserts face challenges in achieving smooth chip discharge, particularly with workpieces of high ductility, as they often have plateau and shoulder parts that hinder backward chip discharge.
Innovation Solution
The cutting insert features a rake surface with a pair of first raised parts extending inward from the cutting edge and a second raised part that extends between them, allowing chips to be curled and drawn onto a rising surface for effective discharge, enhancing wear resistance and chip division.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If plateau part and shoulder part are provided at higher position behind chip deflection surface, then chip discharge performance is improved for some materials, but chip discharge is hindered for workpieces having rich ductility
Solution Approach 1:
The invention applies local quality by providing a rising surface at a specific location on the rake face that is inclined and positioned to receive chips from the cutting edge. This localized structural modification allows chips from ductile materials to be smoothly guided upward and discharged, while other portions of the insert maintain their original functions. The rising surface creates a smooth transition path that prevents chip accumulation specifically in the chip discharge region without affecting other areas of the insert.
Solution Approach 2:
The invention inverts the conventional approach by positioning the rising surface at a lower elevation relative to the plateau and shoulder parts, rather than having all features at high positions. This inverted configuration allows chips to be received at a lower level and gradually elevated along the inclined rising surface, preventing the chip discharge blockage that occurs when chips encounter high-positioned plateau and shoulder parts directly.
2Ease of manufacture
If conventional rake face shape is used, then manufacturing is simpler, but chip discharge performance is insufficient for ductile materials
Solution Approach 1:
The rising surface is added as a localized feature on the rake face, modifying only the specific region needed for chip discharge while leaving the rest of the rake face geometry relatively simple. This approach maintains ease of manufacture for the overall insert while providing the necessary functional improvement in the chip discharge area.
3Reliability
If chips are not properly discharged, then chip remnants remain in machined groove, but workpiece and cutting insert are damaged
Solution Approach 1:
The rising surface performs preliminary action by guiding and elevating chips away from the machined groove before they can accumulate and cause damage. The inclined surface proactively directs chips along a controlled path upward and outward, preventing them from remaining in the groove where they could cause workpiece damage or interfere with subsequent cutting operations.
Solution Approach 2:
The rising surface effectively extracts chips from the critical machined groove region by providing an elevated discharge path. Chips are removed from the low-positioned groove area and transported along the inclined rising surface to a higher discharge location, separating them from the workpiece and preventing harmful interactions.
Data Source
Figure 1(a)~1(b)
Figure 2~3
Figure 4
AI summary
A cutting insert according to an embodiment of the present invention includes an upper surface; a side surface; and a cutting edge located at an intersection region of the upper surface and the side surface. The upper surface includes a rake surface continuous with the cutting edge; and a rising surface inclined and lying at a higher position as going inward from the rake surface. The rake surface includes a pair of first raised parts respectively extending inward from near both ends of the cutting edge in a top view; and a second raised part extending from one of the pair of first raised parts to the other. A cutting tool including the cutting insert, and a method of manufacturing a machined product by using the cutting tool are also provided.