Milling Insert Rake Face Step for Scratch-Free Chip Flow
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Solution Overview
Problem
Cutting inserts for milling often leave scratch marks on processed workpieces due to the constant inclination angle of the rake face relative to the main cutting edge, which causes swarf to contact the workpiece surface, leading to surface imperfections.
Innovation Solution
A cutting insert design featuring a rake face with a level difference portion that crosses the main cutting edge, comprising a rising surface and adjacent regions, which reduces the likelihood of swarf contacting the workpiece surface, thereby minimizing scratch marks. The level difference portion is strategically positioned to alter the swarf outlet direction, preventing surface damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the rake face has a constant inclination angle relative to the main cutting edge, then the cutting insert structure is simple, but scratch marks remain on the processed workpiece surface
Solution Approach 1:
The rake face is divided into multiple regions with different inclination angles: a first rake face portion with a first inclination angle, a second rake face portion with a second inclination angle, and a third rake face portion with a third inclination angle. This segmentation allows each region to perform different functions, preventing swarf from contacting the workpiece surface while maintaining manageable structural complexity
Solution Approach 2:
Different portions of the rake face are given different local properties through varying inclination angles. The first rake face portion has a larger inclination angle to redirect swarf away from the workpiece, while other portions have different angles optimized for their specific functions, achieving high surface quality without excessive overall complexity
2Ease of manufacture
If the rake face inclination angle is constant, then the cutting insert is easy to manufacture, but swarf contacts the workpiece surface causing scratch marks
Solution Approach 1:
The rake face is segmented into distinct portions with different inclination angles, where the first rake face portion has a first inclination angle and the second and third rake face portions have different inclination angles. This segmentation effectively redirects swarf flow to prevent contact with the workpiece surface, reducing scratch marks while maintaining reasonable manufacturability through systematic design
Solution Approach 2:
The inclination angle parameter of the rake face is changed across different portions rather than maintaining a constant value. The first rake face portion has a larger inclination angle compared to other portions, creating the necessary swarf redirection effect to eliminate scratch marks while keeping the overall design manufacturable
Data Source
AI summary
A cutting insert according to the present disclosure includes a first surface, a second surface, a side surface, and a cutting edge. The first surface has a rake face continuous to the cutting edge. The cutting edge has a corner cutting edge, a flat cutting edge, and a main cutting edge. The rake face has a first rake face portion, a second rake face portion, and a third rake face portion, the first rake face portion being continuous to the flat cutting edge, the second rake face portion being continuous to the main cutting edge, the third rake face portion being continuous to the corner cutting edge and being located between the first rake face portion and the second rake face portion. The rake face is provided with a level difference portion.