Double-Sided Cutting Insert Structure for Chip Jamming Prevention
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Solution Overview
Problem
Existing cutting inserts struggle with poor chip disposability when processing difficult-to-cut materials like stainless steel, due to inadequate consideration of chip fluidity in their design.
Innovation Solution
A double-sided cutting insert with a specific geometry, including a flat upper surface boss, inclined cutting edges, and a concavely recessed side portion, is designed to enhance chip flow and prevent jamming.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a helix-type oblique cutting edge structure is employed to improve cutting quality, then cutting quality is improved, but chip fluidity deteriorates causing poor chip disposability
Solution Approach 1:
The invention applies curved surfaces to the chip breaker surface, specifically designing it with a gradually increasing angle relative to the extension line of the upper surface boss portion. This curvature allows chips to flow smoothly along the broken line extending from the cutting edge through the chip breaker surface, preventing jamming while maintaining cutting quality.
Solution Approach 2:
The invention creates different surface characteristics in different regions: the chip breaker surface has a gradually increasing angle for smooth chip flow, while the side portion surface is concavely recessed to guide chips away from the cutting edge. This localized differentiation of surface properties optimizes both cutting quality and chip disposability.
2Manufacturing precision
If the upper mounting surface is formed higher than the lowest part of the cutting edge, then cutting quality is improved, but chip flow is obstructed
Solution Approach 1:
The invention resolves the conflict by introducing a dimensional transition through the concave recess in the side portion surface. This creates a three-dimensional chip flow path that bypasses the obstruction caused by the elevated mounting surface, allowing chips to flow smoothly along the broken line from the cutting edge without being blocked by the upper mounting surface geometry.
3Ease of manufacture
If the chip breaker surface is formed at a single angle, then manufacturing is simplified, but chip fluidity deteriorates for difficult-to-cut materials
Solution Approach 1:
The invention changes the angle parameter of the chip breaker surface from a constant single angle to a gradually increasing angle relative to the extension line of the upper surface boss portion. This parameter variation optimizes chip fluidity for difficult-to-cut materials like stainless steel, allowing chips to flow smoothly along the broken line extending from the cutting edge through the chip breaker surface.
Data Source
AI summary
A cutting insert according to an embodiment of the present invention is a double-sided cutting insert comprising an upper surface, a lower surface, a side surface, a cutting edge, and a mounting hole penetrating the upper surface and the lower surface, in which the upper surface is provided with a single upper surface boss portion that surrounds the mounting hole and is flat, the cutting edge includes a main cutting edge, a corner cutting edge extending from the main cutting edge, a sub-cutting edge extending from the corner cutting edge, and a side portion extending from the sub-cutting edge, a first main cutting edge flank surface extending from the main cutting edge forms an acute angle with an extension line of the upper surface boss portion, a sub-cutting edge chip breaker surface extending from the sub-cutting edge is at a gradually increasing angle with the extension line of the upper surface boss portion, as the sub-cutting edge chip breaker surface is distanced away from the corner cutting edge, and when the cutting insert is viewed into the upper surface, a side portion surface extending from the side portion is concavely recessed.