Cutting Insert Geometry for Fine Finishing and Medium Cutting
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Solution Overview
Problem
Conventional cutting inserts struggle to effectively cover both low-depth-of-cut (fine finishing) and high-depth-of-cut machining operations with a single insert, often resulting in suboptimal chip control and increased burr formation.
Innovation Solution
A cutting insert design featuring a first projection with a decreasing height, a second projection with an increasing top surface, an inclined portion, and a rake portion with a gradually increasing rake angle, which guides and curls the chip to prevent over-restraint and burr formation, allowing for both low-depth-of-cut and high-depth-of-cut machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional cutting insert with a breaker projection is used, then chip control during finishing is ensured, but the insert cannot effectively cover both low-depth-of-cut (fine finishing) and high-depth-of-cut machining operations
Solution Approach 1:
The cutting insert divides the breaker projection into two distinct projections: a first projection with a top surface having height gradually decreasing with distance from the corner portion, and a second projection continued to the first projection with a top surface having height gradually increasing with distance from the first projection. This segmentation allows different regions to serve different machining depths, enabling the insert to cover both low-depth-of-cut and high-depth-of-cut operations while maintaining appropriate chip control for each regime.
Solution Approach 2:
The cutting insert implements local quality by creating spatial variation in the breaker projection structure. The first projection provides a leading end projection for low-depth-of-cut operations, while the second projection provides support for high-depth-of-cut operations. Additionally, the rake portion has a rake angle that gradually increases with distance from the corner portion, providing locally optimized chip flow characteristics for different machining conditions.
2Adaptability or versatility
If a cutting insert with a high-depth-of-cut structure is used, then middle-region machining is enabled, but fine finishing (low-region) performance deteriorates
Solution Approach 1:
The cutting insert implements dynamics through the inclined portion that begins at an intermediate point in the corner cutting edge and extends to the cutting edge, causing the height of the cutting edge to gradually decrease with distance from the corner cutting edge. This dynamic height variation allows the insert to adapt to different depth-of-cut conditions, enabling both fine finishing and middle-region machining with a single insert geometry.
3Manufacturing precision
If the rake angle is increased to inhibit burrs during middle-region machining, then chip flow is improved, but chip restraint becomes excessive in low-region machining
Solution Approach 1:
The cutting insert implements parameter changes by designing the rake portion with a rake angle that gradually increases with distance from the corner portion. This gradual parameter variation allows the insert to provide appropriate chip restraint for low-depth-of-cut operations near the corner portion while progressively increasing the rake angle to inhibit burrs during middle-region machining at greater distances from the corner portion.
Data Source
AI summary
It is intended to allow a wide range including a low region (fine finishing) to a middle region (medium cutting) to be covered with a single insert. A cutting insert includes an upper surface, a lower surface, a peripheral side surface, a cutting edge including a main cutting edge and a corner cutting edge, a corner portion, a projecting portion formed to extend from the corner portion toward a central axis and including a first projection and a second projection, a rake portion, and an inclined portion provided at the cutting edge. The inclined portion has a first inclined portion beginning at an intermediate point in the corner cutting edge, while the rake portion has a shape in which an angular degree of a rake angle gradually increases with distance from the corner portion.