Flat-Top Cutting Tool Rake Structure for Chip Control
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Solution Overview
Problem
Cutting tools with ultra-high pressure sintered diamond bodies face difficulties in creating chip breakers with projections higher than the flat top face, limiting effective chip control.
Innovation Solution
A cutting tool design featuring a flat top face with a cutting edge formed at the corner connecting linear ridge lines, and a fan-shaped rake portion with alternating ridge and groove portions, inclined from the corner toward a pivot, allowing for efficient chip control without a projected portion higher than the cutting edge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the cutting edge is formed by polishing the upper surface to create a flat top face, then the manufacturing precision is improved, but the chip control capability deteriorates due to inability to form projections higher than the flat top face
Solution Approach 1:
The invention transitions from two-dimensional flat surface polishing to three-dimensional fan-shaped ridge and groove structure. The ridge portions extend from the corner R toward the pivot portion P in a radial direction, creating elevated structures that protrude from the flat top face. This dimensional change enables chip breaking functionality while maintaining the precision-polished flat top face as the base structure.
Solution Approach 2:
The rake portion is segmented into alternating ridge portions and groove portions that radiate from the corner R toward the pivot portion P. This segmentation creates multiple chip breaking edges and guidance channels, allowing chips to be controlled and broken effectively without requiring a single high projection, thus maintaining overall flat top face precision.
2Ease of operation
If projections higher than the flat top face are created to improve chip control, then the chip breaker capability is improved, but the manufacturing complexity increases due to difficulty in forming such projections on ultra-high pressure sintered bodies
Solution Approach 1:
The invention changes the geometric parameters of the rake portion by creating fan-shaped ridge and groove structures with specific angular distributions. The ridge portions are arranged radially from corner R to pivot portion P with controlled heights and spacing, enabling effective chip breaking through geometric design rather than requiring complex high-projection formation processes.
3Ease of manufacture
If a flat top face is maintained without projections, then the manufacturing simplicity is improved, but the chip discharge capability deteriorates due to lack of chip breaking structure
Solution Approach 1:
The fan-shaped ridge portions create three-dimensional chip breaking structures that rise from the flat top face, enabling effective chip curling and breaking. The alternating ridge and groove pattern in the radial direction provides multiple chip guidance paths, improving chip discharge capability while maintaining relative manufacturing simplicity through systematic geometric design.
Data Source
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AI summary
The present invention provides a cutting tool which has a flat top face but still has excellent chip control. The cutting tool includes: a peripheral side face; a top face which is a flat top face constituting a part of an upper surface that is depressed except for the portion of the top face; a cutting edge that is formed at least on a ridge line of a corner R connecting two linear ridge lines, out of ridge lines where the peripheral side face and top face cross; and a fan-shaped rake portion including ridge portions and groove portions, which are disposed alternately and are both depressed so as to be inclined from the corner R, where the crossing line with the top face appears in a wave form, toward a pivot portion which is a center of radial portions.