Cutting Insert Vacancy Gradient for Chipping Resistance
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Solution Overview
Problem
Cutting inserts used in heavy intermittent cutting processes are prone to chipping due to lack of sufficient fracture resistance under severe impact conditions, necessitating improvements in their design and material properties.
Innovation Solution
The insert design incorporates specific surface regions with controlled vacancy ratios and diameters, ranging from 0.005-0.04% and 1.5 μm or less in region A1, and 0.05-0.2% and 2 μm or less in region A2, enhancing fracture resistance and toughness, along with a coating layer for wear resistance, using materials like cemented carbides and ceramics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the insert is used in heavy intermittent cutting processes with large impact, then cutting efficiency is improved, but the cutting edge becomes prone to chipping due to insufficient fracture resistance
Solution Approach 1:
The patent applies local quality by creating distinct regions with different vacancy concentrations within the insert base. Region A1 (near surface) has 0.005-0.04 area% vacancies while region A2 (deeper) has 0.05-0.2 area% vacancies. This gradient structure provides surface hardness for cutting edge integrity while maintaining internal toughness for impact resistance, resolving the contradiction between productivity and reliability.
Solution Approach 2:
The patent changes the physical parameter of vacancy concentration at different depths within the base material. By controlling vacancy area ratios to be 0.005-0.04 area% in region A1 and 0.05-0.2 area% in region A2, the material properties are optimized to simultaneously achieve high surface hardness for cutting efficiency and sufficient internal toughness for fracture resistance under impact conditions.
Data Source
AI summary
An insert of the present disclosure includes a base. The base includes a first surface, a second surface connecting to the first surface, and a cutting edge located on at least a part of a ridgeline of the first surface and the second surface. A region within 2.0 mm from the cutting edge in the first surface is a surface region A. A region within 0.5 mm from the surface region A is a region A1. A region within 1.2 mm from the surface region A and the second surface to 2.0 mm from the surface region A and the second surface is a region A2. An area ratio of vacancies in the region A1 is 0.005-0.04 area %, and an area ratio of vacancies in the region A2 is 0.05-0.2 area %. A cutting tool includes a holder including a pocket and the insert located in the pocket.