Cutting Insert With Segmented Grooves For Fracture Resistance
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Solution Overview
Problem
Conventional cutting inserts with groove parts extending from the upper to the lower surface suffer from reduced wall thickness, leading to compromised fracture resistance and increased cutting resistance, particularly when using through holes, which further exacerbates the risk of fracture during cutting operations.
Innovation Solution
The cutting insert features upper and lower concave parts that divide the cutting edges, separated by a continuous thick part along the side face, ensuring consistent wall thickness and reducing cutting resistance while enhancing fracture resistance by distributing stress effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If a groove part is formed to extend from the upper surface to the lower surface of the side face to reduce chip twining, then cutting resistance is reduced, but the wall thickness of the insert cannot be ensured continuously, leading to deteriorated fracture resistance
Solution Approach 1:
The groove part is segmented into an upper groove part extending from the upper surface and a lower groove part extending from the lower surface, both not reaching the opposite surface. This segmentation prevents the groove from completely traversing the insert thickness, thereby maintaining continuous wall thickness and fracture resistance while still achieving chip control benefits in the respective regions.
Solution Approach 2:
The groove parts are localized to specific regions - the upper groove part is positioned in the upper portion of the side face and the lower groove part in the lower portion, with each groove having controlled depth that does not extend through the entire thickness. This local application of grooves achieves chip management in specific zones while preserving overall structural integrity.
2Ease of manufacture
If a through hole is employed to attach the insert, then the insert structure is simplified and ease of manufacture is improved, but the wall thickness of the insert decreases further, exacerbating fracture resistance deterioration
Solution Approach 1:
The attachment structure uses segmented groove parts (upper and lower) that do not completely traverse the insert thickness, creating a segmented approach to material removal that preserves wall thickness while still providing functional benefits for chip control and stress distribution.
Data Source
AI summary
A cutting insert has an upper face, a lower face, a side face, an upper cutting edge, a lower cutting edge and a through hole. The upper face has a substantially polygonal shape. The side face has a first side face and a second side face. The first side face has at least one upper concave part and at least one lower concave part. The at least one upper concave part and the at least one lower concave part are separated from each other through a thick part being continuous along a width direction of the side face. The thick part has a curved region extending in the shape of a wave from one end to the other end in the width direction of the first side face in a side view.