Segmented Drill Insert Breaker Geometry for Chip Discharge
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Solution Overview
Problem
Existing drills face challenges with chip clogging during machining of soft materials like mild steel due to differences in chip shape and generation speed between inner and outer edge inserts, leading to inefficient chip discharge.
Innovation Solution
A cutting insert design with a breaker part featuring inclined segments that vary in distance from the cutting edge, allowing for effective curling and separation of chips, thereby improving chip discharge performance by ensuring stable contact and reduced likelihood of chip clogging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a conventional drill with inner and outer edge inserts is used, then cutting capability is provided, but chip clogging occurs due to soft chip extension
Solution Approach 1:
The breaker part is divided into three segments (first, second, and third segments) with different inclinations and positions. Each segment serves a specific function in chip control: the first segment curls chips, the second segment provides transition, and the third segment separates chips. This segmentation allows systematic control of chip flow to prevent clogging while maintaining cutting capability.
Solution Approach 2:
Different regions of the breaker part have different geometrical properties tailored to local chip control needs. The first segment has a specific inclination for curling, the second segment provides a transition zone, and the third segment has different inclination for separation. This local differentiation optimizes chip control at each stage of chip formation and discharge.
2Adaptability or versatility
If chips are generated by inner and outer edge inserts at different positions, then cutting versatility is achieved, but chip shape differences cause discharge inefficiency
Solution Approach 1:
The breaker part design with its three-segment structure serves multiple functions simultaneously: it curls chips from both inner and outer edge inserts, accommodates different chip shapes generated at different positions, and provides a unified chip discharge path. This multi-functional design allows the same breaker part to effectively handle chips from various cutting locations.
3Ease of operation
If the breaker part is positioned close to the cutting edge, then chip curling is effective, but chip separation is insufficient
Solution Approach 1:
The breaker part extends in the radial direction from the cutting edge, creating a three-dimensional chip control structure. The first segment curls chips near the cutting edge, while the third segment positioned further radially provides chip separation. This dimensional arrangement allows both curling and separation functions to operate effectively at different radial positions.
Data Source
AI summary
A cutting insert may include a first surface and a second surface. The first surface may include a first side, a first corner, a second corner, and a breaker part. The breaker part may include a first segment, a second segment, and a third segment. The first segment may be an inclined surface inclined so as to approach the second surface as going away from the first side. The third segment may be an inclined surface inclined so as to separate from the second surface as going away from the second segment. In a front view of the first surface, a maximum value at a side of the second corner may be greater than a maximum value at a side of the first corner in a distance from the first side to a top portion of the third segment on an orthogonal line with respect to the first side.