Diamond Cutting Insert with Segmented Protrusions
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Solution Overview
Problem
Cutting inserts with cemented carbide breaker walls fail to divide chips effectively during both grooving and cross-feeding, particularly when cutting materials like aluminum alloys, leading to reduced machining accuracy and potential tool failure due to chip twisting.
Innovation Solution
A cutting insert design featuring a diamond edge portion with a chip breaker recess and protruding portions that extend from the edge portion, allowing for chip division in both grooving and cross-feeding, and optimized geometries to reduce chip curl diameter and improve lubrication and cutting fluid supply.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a cemented carbide breaker wall is used, then the structural strength is improved, but the chip division capability deteriorates
Solution Approach 1:
The breaker wall is segmented into multiple protruding portions that extend from the upper surface toward the land surface. These protruding portions create multiple chip breaking zones, allowing chips to be divided into smaller segments as they flow over the cutting edge. This segmentation approach maintains the structural strength of the cemented carbide while providing effective chip division through geometric features rather than relying on a single solid breaker wall.
Solution Approach 2:
The breaker wall features varying local geometries with different protruding portions having different heights, widths, and spacing. This creates zones with different chip breaking characteristics - some areas provide strong chip containment while others allow chip flow and division. The local quality variation enables the breaker wall to simultaneously maintain structural integrity and provide effective chip division in different regions.
2Reliability
If diamond is used for the edge portion, then welding of workpiece to edge portion is reduced, but the material becomes difficult to process and prone to chipping
Solution Approach 1:
The cutting insert uses a composite structure combining diamond sintered compact for the edge portion with cemented carbide for the body. The diamond provides superior welding resistance and cutting performance, while the cemented carbide body provides structural support and is easier to manufacture. This composite material approach allows the diamond edge to maintain its welding-resistant properties while the overall tool structure remains manufacturable and resistant to chipping through the supporting carbide body.
3Manufacturing precision
If a chip breaker recess is provided, then chip division is improved, but the device complexity increases
Solution Approach 1:
The chip breaker recess is formed by segmenting the breaker wall into multiple protruding portions rather than creating a complex cavity structure. This segmentation approach achieves effective chip division through simple geometric features that extend from the upper surface, avoiding the need for complex recess geometries while maintaining superior chip breaking performance.
Solution Approach 2:
Instead of creating a recessed chip breaker structure that requires complex cavity formation, the invention inverts the approach by projecting breaker wall portions outward from the upper surface. This inverted geometry achieves chip breaking functionality through protruding features rather than recessed cavities, significantly simplifying the manufacturing process while maintaining effective chip division capability.
Data Source
AI summary
The edge portion includes an upper surface, a side surface, and a land surface. The side surface has a front side surface and a pair of lateral side surfaces. An intersection between the land surface and the front side surface forms a front cutting edge. An intersection between the land surface and each of the pair of lateral side surfaces form a corresponding one of a pair of lateral cutting edges. The edge portion contains 80 vol % or more of diamond. A chip breaker recess is provided between the upper surface and the land surface. The surfaces forming the chip breaker recess include a rake face and a breaker wall surface. The upper surface has a front edge portion opposite to the front cutting edge from the chip breaker recess. A pair of protruding portions are provided to extend from the front edge portion toward the front cutting edge.