Multi-Angle Corner Insert for Chip Control
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Solution Overview
Problem
Existing cutting inserts are not suitable for both high and low feed rates, especially at small depths of cut, as they either deform or cause chip clogging, leading to instability and inefficiency in machining processes.
Innovation Solution
The insert features a unique corner region with specifically angled corner surfaces that guide and curl chips effectively, preventing clogging and ensuring stability across varying feed rates and depths of cut, utilizing a combination of inclined surfaces to manage chip flow and load distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional insert design with simple corner surfaces is used, then the device complexity is low, but chip clogging occurs and cutting stability deteriorates at high feed rates and small depths of cut
Solution Approach 1:
The corner region is segmented into multiple distinct surfaces (first corner surface, second corner surface, third corner surface, fourth corner surface) with different inclination angles. Each surface performs a specific function in guiding and curling chips, replacing a single simple surface with a segmented multi-surface structure to prevent chip clogging while maintaining cutting stability.
Solution Approach 2:
Different surfaces within the corner region are given different local qualities through varying inclination angles. The first corner surface has a smaller inclination angle for initial chip guidance, while the second corner surface has a larger inclination angle for effective chip curling. This local differentiation allows each surface to optimize its function for specific chip flow conditions.
2Productivity
If the insert is designed for high feed rate cutting, then productivity is improved, but chip clogging and instability occur at small depths of cut
Solution Approach 1:
The corner region design creates dynamic chip curling behavior that adapts to different cutting conditions. At high feed rates with small depths of cut, the multi-surface structure dynamically guides chips through a controlled curling path, preventing clogging while maintaining the high productivity required. The varying inclination angles allow the system to dynamically respond to chip flow characteristics.
3Adaptability or versatility
If a single inclination angle is used for corner surfaces, then the device complexity is low, but the insert cannot effectively manage chips at both low and high feed rates
Solution Approach 1:
The corner region with multiple surfaces of different inclination angles serves multiple functions: the first corner surface guides chips at lower angles, the second corner surface curls chips at higher angles, and the third and fourth surfaces provide additional control. This multi-functional design allows a single insert to effectively manage chips across a wide range of feed rates, from low to high, without requiring different inserts for different conditions.
Data Source
AI summary
An insert includes an upper surface including at least one corner part and a plurality of side parts, and a side surface. The upper surface includes a corner region. The corner region includes a first corner surface, a second corner surface, a third corner surface, and a fourth corner surface which are located sequentially in order from a side of the corner part. The first corner surface is inclined downward. The second corner surface, the third corner surface and the fourth corner surface are inclined upward. An inclination angle θ12 of the second corner surface is greater than an inclination angle θ13 of the third corner surface. An inclination angle θ14 of the fourth corner surface is greater than the inclination angle θ12 of the second corner surface.