Grooved Cutting Insert Diagonal Segmentation for Chip Removal
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Solution Overview
Problem
Existing cutting inserts do not efficiently facilitate the removal of chips from a workpiece, as they lack effective geometries to enhance chip formation and removal processes.
Innovation Solution
The cutting insert features a first and second mounting surface, a first and second side surface, and diagonally extending grooves that divide the side surfaces into discrete support surfaces, with rake surfaces forming non-zero angles to improve chip formation and removal. The grooves are designed to facilitate the flow and removal of chips, with configurations such as U-shaped and V-shaped grooves that intersect with the support surfaces at specific angles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a flat grooved surface is used, then the structure is simple, but chip removal efficiency is poor
Solution Approach 1:
The groove is divided into multiple segments including a first groove segment, a second groove segment, and an optional third groove segment. Each segment serves a specific function: the first segment forms an inclusion zone, the second segment creates an exclusion zone, and the third segment provides a transition. This segmentation allows chips to be effectively contained and removed while maintaining a manageable structural complexity.
Solution Approach 2:
Different portions of the groove are given different geometric properties. The groove width varies along its length, with specific widths at different segments. The groove depth also varies, creating zones of inclusion and exclusion. This local differentiation optimizes chip removal at each stage of the cutting process without requiring complete redesign of the entire groove structure.
2Productivity
If groove width is increased to facilitate chip flow, then chip removal improves, but support surface area decreases
Solution Approach 1:
The groove width is designed to be dynamic rather than uniform. It varies along the length of the groove, being narrower at certain segments and wider at others. This dynamic geometry allows the groove to provide adequate support surface area in regions where width is constrained, while still providing sufficient chip flow capability in regions where width is increased.
Solution Approach 2:
Instead of solving the contradiction by only adjusting groove width in one dimension, the invention utilizes multiple dimensions including groove depth, groove width variation, and groove positioning. The groove is positioned at a specific distance from the cutting edge, and its cross-sectional geometry varies along its length, effectively using dimensional variations to balance support area and chip flow capability.
Data Source
Figure 1A~1E
Figure 1G~3
Figure 4B~4C
AI summary
A cutting insert (21, 21') includes a first mounting surface (23, 23'), a second mounting surface (25, 25') on an opposite side of the insert (21, 21') from the first mounting surface (23, 23'), and a first side surface (27, 27') between the first mounting surface (23, 23') and the second mounting surface (25, 25'). The insert (21, 21') further includes a first groove (35) extending substantially diagonally across the first side surface (27, 27') and dividing the first side surface (27, 27') into discrete, separated, triangular first and second first side support surfaces (37 and 39), the first and second first side support surfaces (37 and 39) each being bounded along first and second edges thereof by rake surfaces (59, 65) forming non-zero angles with the first and second side support surfaces and along third edges thereof by the groove (35).