Cutting Tool Rake Face with Guide Body for Chip Breaking
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Solution Overview
Problem
Existing cutting tools face challenges in achieving a wide range of applications and improved machining processes, particularly under difficult conditions, due to issues with chip breaking and tool wear, especially when dealing with non-ferrous metals or plastics.
Innovation Solution
The ultra-hard layer behind the cutting edge is recessed down to the base layer, and a guide body with an inclined or concavely rounded chip guiding surface is positioned above the ultra-hard layer, allowing for effective chip deflection and breaking, with varying depression widths depending on machining type and depth.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a guide body is positioned close to the cutting edge to improve chip breaking, then chip deflection is enhanced, but the cutting edge becomes vulnerable to breakage
Solution Approach 1:
The cutting tool surface is segmented into distinct functional zones: a countersink depression zone for initial chip deflection, an elevation zone for chip containment, and a guide body zone for final chip breaking. This segmentation allows each zone to perform its function optimally without compromising the cutting edge integrity.
Solution Approach 2:
The invention introduces a third dimension (depth) by creating a countersink depression and elevation in the rake face, transforming a two-dimensional surface into a three-dimensional chip control structure. This allows chip deflection to occur progressively through multiple levels rather than at a single point close to the cutting edge.
2Reliability
If chips are compressed at the corner between rake face and chip guiding surface, then chip breaking occurs, but material deposits and increased wear result
Solution Approach 1:
The harmful compression zone at the corner is eliminated by extracting the chip breaking function to a separate guide body positioned behind the elevation. Chips are deflected smoothly through the countersink and elevation without being compressed against the rake face, preventing material deposits and reducing wear.
3Adaptability or versatility
If the depression depth is increased to improve chip breaking under difficult conditions, then chip deflection is enhanced, but the complexity of the tool structure increases
Solution Approach 1:
The diamond layer is recessed to different depths in different local zones: a first depth to form the countersink depression and a second greater depth to form the elevation. This local variation in depth creates effective chip breaking geometry without requiring uniform deep recessing throughout the entire tool structure.
Data Source
Figure 1b~3
AI summary
Cutting tool comprises an ultra-hard layer (14) recessed up to a support layer (16) directly behind a groove (26) and a guiding body (20) fixed in the recess on the support layer to be lifted over the ultra-hard layer and provided with a slanted or rounded guiding surface (22, 24). Preferred Features: The guiding surface of the guiding body has a steep rise in relation to the plane of the cutting edge (10).