Cutting Insert with Segmented Grooves for Chip Control
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Solution Overview
Problem
Existing cutting inserts face challenges in the grooving and shoulder grooving processes due to inadequate chip discharge performance, leading to unstable chip direction and potential damage to machined surfaces, as they require a large distance between ridges for effective chip curvature, which compromises the cutting edge length and stability.
Innovation Solution
A cutting insert design featuring a concave-shaped cutting edge with protruded parts and second concave grooves that allow for adjustable cutting edge lengths, improved chip compression, and stabilized chip discharge, enhancing performance in both grooving and shoulder grooving processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a large distance is ensured between the pair of ridges to curve chips in the width direction, then chip discharge performance is improved, but the cutting edge length for shoulder grooving is insufficient
Solution Approach 1:
The cutting insert is divided into multiple functional zones: a grooving zone with ridges for chip curling, and a shoulder grooving zone with a wider top surface and longer cutting edge. This segmentation allows each zone to be optimized for its specific function without compromising the other.
Solution Approach 2:
Different regions of the cutting insert have different geometric properties: the grooving region has closely spaced ridges for effective chip curling, while the shoulder grooving region has a larger top surface width and longer cutting edge for width expansion. This local differentiation resolves the contradiction by providing appropriate geometry for each specific operation.
2Ease of operation
If ridges are formed to become higher as separating from the major cutting edge to guide chips, then chip guidance is improved, but chip curling diameter increases and discharge stability deteriorates
Solution Approach 1:
The ridge geometry is optimized by controlling the height and spacing parameters. The ridges are positioned and dimensioned to achieve effective chip guidance while maintaining an appropriate curling diameter for stable discharge, balancing guidance effectiveness with discharge stability.
3Reliability
If the top surface width located further outward than the ridges is made small to accommodate ridge spacing, then grooving performance is maintained, but shoulder grooving performance is insufficient
Solution Approach 1:
The top surface is segmented into different functional zones: a narrower region over the ridges for effective grooving with proper chip curling, and a wider region outward from the ridges for shoulder grooving operations. This allows each zone to have the appropriate dimensions for its specific function.
Solution Approach 2:
Different portions of the top surface have different widths tailored to their functions: the region above the ridges maintains appropriate width for grooving, while the outer region is widened to provide sufficient cutting edge length for shoulder grooving operations.
Data Source
Figure 1(a)~1(c)
Figure 2
Figure 3
AI summary
In a cutting insert according to an embodiment of the present invention, an upper surface includes: a first concave groove which is continuous with a first cutting edge and extends along a longitudinal direction; a pair of second concave grooves which are respectively continuous with a pair of second cutting edges and extend along the longitudinal direction; and a pair of protruded parts respectively located between the first concave groove and the pair of second concave grooves. The pair of protruded parts are respectively continuous with an end surface cutting edge and are separated from each other by a larger distance therebetween as separating from the end surface cutting edge. A cutting tool with the cutting insert, and a method of manufacturing a machined product by using the cutting tool are also provided.