Cutting Insert Concave Surface for Chip Curling Control

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Solution Overview

Problem

Existing cutting inserts face challenges in efficiently managing chip discharge during cutting processes, leading to potential chip clogging and damage to machined surfaces due to unstable chip flow and curling.

Innovation Solution

The design of cutting inserts with a concave or convex part on their surfaces guides chip flow, ensuring effective chip division and discharge by bending chips orthogonal to their extending direction, thereby preventing curling and clogging.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a conventional cutting insert with a flat surface is used, then the structure is simple and easy to manufacture, but chip flow becomes unstable causing chip curling and clogging

Engineering Contradiction:

Improvechip discharge performanceVSAvoidinsert structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The cutting insert incorporates a concave portion with a curved surface on its top surface. This curvature guides chip flow smoothly along the concave surface, preventing chip curling and unstable flow. The curved geometry transforms the flat surface into a chip-guiding channel that maintains stable chip discharge while the insert remains a simple solid structure suitable for conventional manufacturing processes.

Inventive Principle:

Principle #14Spheroidality (Curvature)

2Reliability

If the cutting insert surface is modified to guide chip flow, then chip discharge performance improves, but the manufacturing process becomes more complex

Engineering Contradiction:

Improvechip discharge performanceVSAvoidinsert fabrication

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The concave portion is designed with specific geometric parameters including a controlled depth (0.1-0.5 times the insert thickness) and curvature radius. By optimizing these parameters, the insert achieves effective chip guidance while maintaining compatibility with conventional manufacturing methods such as CNC machining or mold making, avoiding the need for complex additive manufacturing or specialized forming processes.

Inventive Principle:

Principle #35Parameter changes

3Productivity

If chips are allowed to flow freely without guidance, then the insert structure remains simple, but chip clogging and surface damage occur

Engineering Contradiction:

Improvecutting efficiencyVSAvoidchip clogging and surface damage

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The concave portion acts as an intermediary structure between the cutting edge and the chip discharge path. It provides a guided channel that mediates chip flow, preventing direct chaotic ejection of chips. This intermediary structure ensures smooth chip transport away from the cutting zone, eliminating clogging and surface damage while maintaining cutting efficiency.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS11325195B2Insert

Publication Date: 2022.05.10 KYOCERA CORP

AI summary

An insert may include a first surface, a second surface, a ridge line located at an intersection of the first surface and the second surface. The first surface may include a first corner, a first side and a second side. The ridge line may include a corner cutting edge located on the first corner, a first cutting edge located on the first side, and a second cutting edge located on the second side. The first surface may further include a first region located from the first cutting edge toward a midportion of the first surface, a second region located from the second cutting edge toward the midportion of the first surface, and a concave part located on at least one of the first region and the second region.