Indexable Insert Cutting Edge Curvature for Chip Control
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Solution Overview
Problem
Conventional indexable insert drills face issues with chip discharge, where long spiral chips generated at low cutting speeds can cause damage to processing apparatus due to their weight and tendency to clog the chip discharge flute.
Innovation Solution
The insert design features a unique cutting edge configuration with convex curvilinear shapes and varying radii of curvature, which curvatures the chip into a stable spiral shape, reducing its weight and preventing clogging by obstructing its extension into a spiral shape, thereby increasing the chip pitch and minimizing the risk of damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional indexable insert drills are used, then cutting operation can be performed, but long spiral chips are generated that cause damage to processing apparatus due to their weight and clogging of chip discharge flute
Solution Approach 1:
The cutting edge incorporates convex curvilinear shapes with specific radii of curvature (first radius R1 and second radius R2 where R2 < R1) to curve the chip into a stable spiral shape. This curvature control transforms the chip morphology from long spiral to controlled spiral with increased pitch, reducing chip weight and preventing apparatus damage while maintaining cutting capability
2Manufacturing precision
If cutting speed is low, then precise cutting can be achieved, but long spiral chips are generated that clog chip discharge flute and damage processing apparatus
Solution Approach 1:
The convex curvilinear cutting edge with varying radii of curvature actively shapes the chip during low-speed cutting operations. The first radius R1 and second radius R2 create a controlled spiral chip form with increased pitch, preventing chip clogging in the discharge flute and eliminating damage risks even when operating at low cutting speeds where high precision is required
3Stability of the object's composition
If chip pitch is small, then cutting operation is stable, but chip mass per unit length increases causing damage to processing apparatus
Solution Approach 1:
The convex curvilinear cutting edge geometry with specific radius relationships (R2 < R1) increases the chip pitch by curving the chip into a stable spiral shape. This increases the volume occupied by each chip segment, thereby reducing the mass per unit length while maintaining cutting stability through the controlled spiral formation
Data Source
AI summary
In an embodiment, an insert includes an upper surface including a corner part, a lower surface, a side surface, and a cutting edge. The side surface is between the upper surface and the lower surface. The cutting edge is at least at a part of a first region in which the upper surface intersects with the side surface. The cutting edge includes a first cutting edge at the corner part, a second cutting edge, a third cutting edge, and a fourth cutting edge. The second cutting edge is next to the first cutting edge, and also next to the third cutting edge. The third and fourth cutting edges: each have a convex curvilinear shape with first and second radii of curvature, respectively; and extend downward and upward, respectively, in a side view as going farther from the second cutting edge. The second radius smaller than the first radius.