Cutting Insert Wiper Edge Segmentation for Surface Finish
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Solution Overview
Problem
Conventional cutting inserts with wiper edges in milling tools often result in excessively small chip thickness, leading to a roughened workpiece surface and deteriorated finish due to large overlapping areas during repetitive cutting.
Innovation Solution
A cutting insert design featuring a wiper edge with a combination of first and second wiper edges of different radii of curvature, where the first wiper edge has a relatively small radius and the second wiper edge has a larger radius, reducing excessive cutting and improving surface finish by controlling chip thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a wiper edge with large radius of curvature is used, then the cutting insert can finish the processed surface, but the chip thickness becomes excessively small causing gouge phenomenon and rough surface
Solution Approach 1:
The wiper edge is segmented into multiple sections with different radii of curvature (first wiper edge section with smaller radius, second wiper edge section with larger radius). This segmentation allows different portions of the wiper edge to perform different functions: the first section maintains appropriate chip thickness while the second section provides the finishing action, thereby preventing gouge phenomenon while achieving good surface finish.
Solution Approach 2:
Different sections of the wiper edge are given different local properties (different radii of curvature) to optimize their respective functions. The first wiper edge section has a smaller radius suitable for maintaining chip thickness, while the second section has a larger radius suitable for surface finishing. This local differentiation resolves the contradiction between preventing gouging and achieving smooth finish.
2Productivity
If a straight line shaped wiper edge is used, then the cutting insert can remove material, but the overlapping area between successive cuts becomes large reducing productivity
Solution Approach 1:
The wiper edge is designed with curved geometry instead of a straight line, incorporating sections with different radii of curvature. This curvature reduces the overlapping area between successive cuts by optimizing the cutting path, thereby improving productivity while maintaining surface finish quality through the differentiated radius sections.
Data Source
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AI summary
A cutting insert according to an embodiment has a polygonal shaped upper surface, a lower surface, a side surface, and a cutting edge. The cutting edge has an arc-shaped first corner edge, an arc-shaped second corner edge, and a wiper edge located between the first corner edge and the second corner edge. The wiper edge has an arc-shaped first wiper edge and an arc-shaped second wiper edge located closer to the second corner edge than the first wiper edge. R0<R1<R2 is satisfied wherein R1 is a radius of curvature of the first wiper edge, R2 is a radius of curvature of the second wiper edge, and R0 is a radius of curvature of each of the corner edges in a top view.