Indexable Cutting Insert Serrations Reduce Composite Delamination
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Solution Overview
Problem
Composite materials like fiber reinforced plastic (FRP) tend to delaminate during machining using cutting inserts with only positive axially raked cutting edges.
Innovation Solution
An indexable cutting insert with a plurality of cutting edges featuring both positive and negative axial rake angles, achieved through the incorporation of triangular-shaped serrations along the cutting edges, providing equal numbers of identical serrations on each edge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cutting inserts with only positive axially raked cutting edges are used, then machining capability is provided, but delamination occurs during machining of composite materials
Solution Approach 1:
The cutting edge is segmented into multiple discrete serrations along its length, with each serration having a different axial rake angle. This segmentation allows different portions of the cutting edge to interact with the composite material layers differently, preventing delamination while maintaining effective cutting.
Solution Approach 2:
Different segments of the cutting edge are given different local properties through varying axial rake angles. Some serrations have positive axial rake angles for efficient material removal, while others have negative axial rake angles to support and prevent delamination of the composite layers.
2Reliability
If serrations with both positive and negative axial rake angles are incorporated, then delamination is reduced, but cutting insert complexity increases
Solution Approach 1:
The complex cutting edge geometry is achieved through segmentation into standardized serration units. Each serration is a discrete triangular-shaped element with specific dimensions, allowing the complex overall geometry to be built from repeating modular components that can be manufactured consistently.
Solution Approach 2:
The cutting insert itself is made of composite material (cemented carbide), and the cutting edge geometry mimics this composite approach by combining different rake angle segments. This allows the complex geometry to be integrated into the existing composite material structure of the insert.
Data Source
AI summary
An indexable cutting insert includes a top surface, a bottom surface, a plurality of peripheral side surfaces, and a plurality of cutting edges formed at an intersection between said top surface and plurality of side surfaces. A plurality of triangular-shaped serrations are positioned along the cutting edges, each serration comprising an apex and a pair of side surfaces that meet at a vertex. The serrations provide the cutting edges with both a positive axial rake angle and a negative axial rake angle, thereby reducing delamination when machining a composite material.