Grooved Cutting Insert Rake Surface for Coolant Flow and Edge Strength
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Solution Overview
Problem
Existing cutting inserts made of cemented carbide, cermet, or ceramics face challenges in high-speed machining due to temperature rise and wear resistance, with coolant channels not effectively enhancing cooling and leading to chip retention and cutting edge fracture.
Innovation Solution
The insert design incorporates grooves on the rake surface at specific angles and distances from the cutting edge, forming micro-channels for coolant flow, reducing friction and preventing chip retention, while maintaining cutting edge integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If coolant grooves are disposed on the rake surface to enhance cooling effect, then cooling efficiency is improved, but chip retention occurs and cutting edge fracture resistance deteriorates
Solution Approach 1:
The rake surface is segmented into multiple zones with different groove configurations. The first groove is positioned at a specific distance from the cutting edge to prevent chip retention, while the second groove is positioned further away to enhance cooling. This segmentation allows each groove to serve its specific function without interfering with cutting edge integrity.
Solution Approach 2:
Different regions of the rake surface are given different groove characteristics. The groove closer to the cutting edge has different depth and spacing parameters compared to grooves further away, optimizing each local region for its specific function - chip evacuation near the edge and cooling further away.
2Temperature
If grooves are placed closer to the cutting edge to improve cooling, then cooling effect is enhanced, but cutting edge strength deteriorates
Solution Approach 1:
The groove configuration is designed in advance with specific distance parameters from the cutting edge. The first groove is positioned at an optimal distance that preliminary prevents chip retention while the second groove provides cooling at a safer distance, thus preventing cutting edge fracture before it occurs.
Solution Approach 2:
Instead of using a single deep groove close to the cutting edge that would compromise edge strength, the design uses multiple shallower grooves at different distances. This distributes the structural impact and maintains cutting edge integrity while achieving cooling functionality.
3Temperature
If multiple grooves are added to enhance cooling and reduce friction, then cooling efficiency is improved, but device complexity increases
Solution Approach 1:
The grooves are configured to provide continuous cooling and chip evacuation functionality. The first and second grooves work together in a continuous manner - the first groove handles chip evacuation while the second groove provides cooling, creating a continuous useful action that maintains cutting edge temperature control throughout the machining process.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The grooved design enhances cooling efficiency, reduces cutting force, and improves fracture resistance, enabling high-speed machining with extended tool life.
Implementation Method 1
a plurality of grooves that serve as a flow path for the coolant are disposed on a rake surface of the insert
Implementation Method 2
The grooved design enhances cooling efficiency, reduces cutting force
Data Source
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AI summary
An insert of the present disclosure includes a base. The base includes a first surface, a second surface connecting to the first surface, and a cutting edge located on at least a part of a ridgeline of the first surface and the second surface. The first surface includes a plurality of grooves located at a position away from the ridgeline and extended at an angle of 20-90° relative to the ridgeline. The grooves are away from the ridgeline in a range of 40-700 µm. A width W of the grooves is 50-700 µm, and a depth D of the grooves is 20-700 µm. Spacing S between the grooves adjacent to each other is 50-700 µm. A cutting tool of the present disclosure includes a holder, which has a length extending from a first end to a second end and includes a pocket located on a side of the first end, and the insert located in the pocket.