Cutting Insert Segmented Edges for Surface Finish
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Solution Overview
Problem
Conventional cutting inserts face challenges in maintaining surface smoothness during machining, especially when processing conditions change, such as in sinking machining, where the machined surface unevenness is difficult to minimize due to the linear shape of the wiper.
Innovation Solution
A cutting insert design featuring a polygonal upper surface with multiple corner portions and sides, including first, second, third, and fourth cutting edges with specific curved and linear shapes, where the second cutting edge is linear for parallel machining and the third cutting edge is convex curved for inclined machining, enhancing surface smoothness by adapting to varying processing conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a linear-shaped wiper is used for parallel machining, then surface smoothness is improved, but surface unevenness increases during inclined machining
Solution Approach 1:
The cutting insert is divided into multiple functional segments: a linear-shaped second cutting edge for parallel machining and a convex curved-shaped third cutting edge for inclined machining. This segmentation allows each segment to specialize in specific machining conditions, resolving the contradiction between optimizing for parallel machining and adapting to inclined machining.
Solution Approach 2:
Different regions of the cutting insert are given different geometric properties: the second cutting edge has a linear shape optimized for parallel machining, while the third cutting edge has a convex curved shape optimized for inclined machining. This local differentiation enables the insert to maintain surface smoothness across varying processing conditions.
2Manufacturing precision
If a convex curved wiper is used for inclined machining, then surface smoothness is improved, but surface unevenness increases during parallel machining
Solution Approach 1:
The cutting insert is divided into multiple functional segments: a convex curved-shaped first cutting edge for inclined machining and a linear-shaped second cutting edge for parallel machining. This segmentation allows each segment to specialize in specific machining conditions, resolving the contradiction between optimizing for inclined machining and adapting to parallel machining.
Solution Approach 2:
Different regions of the cutting insert are given different geometric properties: the first cutting edge has a convex curved shape optimized for inclined machining, while the second cutting edge has a linear shape optimized for parallel machining. This local differentiation enables the insert to maintain surface smoothness across varying processing conditions.
3Ease of manufacture
If a single linear wiper geometry is used, then manufacturing simplicity is improved, but surface finish quality deteriorates under varying processing conditions
Solution Approach 1:
The wiper is segmented into multiple cutting edges with different geometries (convex curved first cutting edge, linear second cutting edge, convex curved third cutting edge) instead of using a single uniform geometry. This segmentation enables each segment to be optimized for specific machining conditions, improving surface finish quality across varying processing conditions while maintaining reasonable manufacturing complexity.
Data Source
AI summary
In an embodiment, a cutting insert includes an upper surface, a one or more side surfaces, and a cutting edge. The upper surface includes a first corner portion, and a first side that is adjacent to the first corner portion. The side surfaces are adjacent to the upper surface. The cutting edge is disposed on at least a portion of a section where the upper surface and the side surfaces intersect. The cutting edge includes first, second, third and fourth cutting edges. The first cutting edge is disposed at the first corner portion and has a convex curved shape. The second cutting edge is next to the first cutting edge, and has a linear shape. The third cutting edge is next to the second cutting edge, and has a convex curved shape. The fourth cutting edge is next to the third cutting edge on the first side.