Cutting Insert Inclined Protrusions for Chip Clogging Resistance
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Solution Overview
Problem
Existing cutting inserts face challenges in efficiently handling chip flow and preventing chip clogging during cutting processes, especially under varying cutting conditions such as large depth of cut and high feed rates, leading to reduced durability and performance.
Innovation Solution
The cutting insert design features a first and second protrusion with inclined surfaces that control chip flow direction, reducing the likelihood of chip clogging and wear, and includes a configuration that maintains stability across different cutting conditions through a combination of convex and concave shapes and inclined surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional cutting insert design is used, then manufacturing simplicity is maintained, but chip discharge performance deteriorates and chip clogging occurs
Solution Approach 1:
The cutting insert is divided into multiple functional protrusions (first protrusion with inclined surface, second protrusion, third protrusion) that segment the chip flow path. Each protrusion performs a specific function in controlling and directing chips, preventing clogging while maintaining overall structural integrity.
Solution Approach 2:
Different regions of the cutting insert are given different geometric properties tailored to local requirements. The inclined surface of the first protrusion has specific inclination angles (α1, α2) optimized for chip flow, while the second and third protrusions have different shapes and positions optimized for their respective locations in the chip path.
2Adaptability or versatility
If single protrusion design is used, then device complexity is reduced, but chip flow control capability is insufficient under varying cutting conditions
Solution Approach 1:
The cutting insert design with multiple protrusions creates a universal solution that adapts to various cutting conditions (different depths of cut, feed rates, and material types). The combination of inclined surface and additional protrusions provides multi-functional chip control that works across a wide range of machining parameters.
3Reliability
If simple rake surface geometry is used, then manufacturing ease is improved, but chip clogging and wear increase
Solution Approach 1:
The inclined surface of the first protrusion features curved geometry with specific inclination angles rather than flat planes. This curvature helps guide chips smoothly along the rake surface, preventing abrupt changes in chip direction that would cause clogging and reduce wear on the insert.
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 first protrusion and a second protrusion. The first protrusion may be extended toward the first corner. The second protrusion may be located between the first corner and the first protrusion. The first protrusion may include an inclined surface. The inclined surface may be located along the first side. The inclined surface may include a first surface and a second surface. The second surface may be located further away from the first corner than the first surface. The first surface and the second surface may be individually inclined upward as going away from the first side, and having a concave shape as a whole.