Cutting Insert Bottom Surface Layout for Stable Chip Discharge
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Solution Overview
Problem
Existing cutting inserts face challenges in achieving stable chip behavior and reducing chip clogging during both shallow and deep cut operations, particularly due to unstable chip formation and inadequate chip discharge mechanisms.
Innovation Solution
The cutting insert design features a polygonal upper surface with acute and obtuse corners, a rake surface, and inclined bottom surfaces that guide chip flow, ensuring stable chip formation and discharge by providing multiple contact points for chip support and directing chip flow effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional cutting insert design is used, then the structure is simple, but chip discharge performance is poor and chip clogging occurs
Solution Approach 1:
The bottom surface is divided into multiple inclined surfaces (first inclined surface, second inclined surface, third inclined surface) with different orientations. Each inclined surface segment guides chips in specific directions, creating multiple chip flow paths that prevent clogging while maintaining overall structural efficiency
Solution Approach 2:
The invention introduces multi-dimensional chip guidance by creating inclined surfaces at various angles (including angles greater than 45 degrees relative to the cutting edge). This multi-directional approach guides chips away from the cutting zone in three-dimensional space, improving discharge performance without complicating the basic insert structure
2Reliability
If the rake surface is extended further, then chip support is improved, but the insert height increases
Solution Approach 1:
The bottom surface is segmented into multiple inclined surfaces rather than using a single extended rake surface. This segmentation provides distributed chip support across different zones, maintaining stable chip formation without requiring increased insert height
Solution Approach 2:
Different regions of the bottom surface have different inclinations optimized for specific functions: the first inclined surface provides initial chip guidance, the second inclined surface (at angles >45 degrees) provides strong chip support and direction, and the third inclined surface completes the chip discharge path. This localized optimization achieves reliable chip support within compact dimensions
3Productivity
If multiple chip discharge paths are created, then chip clogging is reduced, but device complexity increases
Solution Approach 1:
Multiple chip discharge functions are merged into a single integrated bottom surface structure. The first, second, and third inclined surfaces work together as one unified chip guidance system, creating multiple discharge paths without requiring separate components or complex mechanisms
Solution Approach 2:
The bottom surface serves multiple functions simultaneously: chip guidance, chip support, chip direction, and discharge facilitation. The inclined surfaces collectively perform all these functions in a compact, unified structure that does not increase overall device complexity
Data Source
AI summary
A cutting insert in a non-limiting aspect of the present disclosure may include an upper surface, a lower surface, a lateral surface and a cutting edge. The upper surface may include a first corner and a first side. The upper surface may further include a rake surface, a bottom surface and a raised surface. The bottom surface may include a first bottom surface and a second bottom surface. The first bottom surface may be located on a bisector of the first corner. The second bottom surface may be located inwardly of the first side. The first bottom surface may be an inclined surface located closer to the lower surface as going away from the first corner. The second bottom surface may be an inclined surface located further away from the lower surface as going away from the first side.