Cutting Insert With Varying Rake Angles To Reduce Wear
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Solution Overview
Problem
Existing cutting inserts suffer from damage to the rake face due to high feed rates and chip collisions, particularly when the rake angle is large and the insert is thin, leading to wear and reduced cutting performance.
Innovation Solution
A cutting insert with a top surface having a polygonal shape and inclined surfaces with varying rake angles, including a first inclined surface with a greater angle than a second inclined surface, to manage chip flow and reduce wear by stabilizing chip curling and decreasing cutting resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the rake angle is increased to decrease cutting resistance, then cutting resistance decreases, but the thickness of the cutting insert between side surfaces and the rake face decreases, causing the rake face to wear and become damaged due to chip collision
Solution Approach 1:
The patent applies different rake angles to different regions of the rake face. The first rake face portion has a first rake angle while the second rake face portion has a second rake angle that is different from the first. This allows the region experiencing chip collision (second rake face portion) to have a smaller rake angle for increased strength, while the first rake face portion maintains a larger rake angle for reduced cutting resistance.
Solution Approach 2:
The rake face is divided into two distinct portions: a first rake face portion and a second rake face portion. Each portion has a different rake angle optimized for its specific function. The first rake face portion handles the initial chip flow with a larger rake angle, while the second rake face portion provides structural support and chip guidance with a smaller rake angle.
2Productivity
If the rake angle is large and the cutting insert is thin, then cutting resistance is reduced, but chip collision at high feed rates causes the rake face to wear and become damaged
Solution Approach 1:
Different regions of the rake face are assigned different rake angles based on their functional requirements. The first rake face portion with the larger rake angle facilitates chip flow during high feed rate operations, while the second rake face portion with the smaller rake angle provides enhanced durability and resistance to chip collision in the region where chips accumulate and collide.
Data Source
AI summary
A cutting insert of one aspect is provided with a top surface having a polygonal shape and including a corner portion, a first side and a second side, each extending from the corner portion, a bottom surface, a side surface, and a cutting edge. The cutting edge includes a corner cutting edge disposed in a position corresponding to the corner portion, and a first cutting edge disposed in a position corresponding to the first side. The top surface includes an inclined surface provided with a first inclined surface disposed along the first side, a second inclined surface disposed along the second side, and a third inclined surface disposed along the corner portion. An inclination angle of the first inclined surface is greater than an inclination angle of the second inclined surface.