Multi-Corner Cutting Insert for Better Chip Discharge
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Solution Overview
Problem
Cutting inserts with multiple corners face challenges in chip discharge performance due to the shape of their cutting edges, leading to chips being caught between the flank and the work material, especially when the space between the flank and the finished surface is small.
Innovation Solution
A cutting insert design featuring a ridgeline with multiple corners, where the second cutting edge is positioned closer to the center and has a larger clearance angle than the first cutting edge, creating a larger space for chip discharge, and a recessed third side surface to further enhance this space, while maintaining economic efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a cutting insert has a large number of corners (e.g., regular octagonal shape), then economic efficiency is improved, but cutting edge length becomes shorter and chip discharge performance deteriorates
Solution Approach 1:
The patent applies local quality by creating different clearance angles at different locations of the cutting insert. Specifically, the first circumferential side surface has a first clearance angle while the second circumferential side surface has a second clearance angle that is larger than the first. This local differentiation allows the cutting insert to maintain multiple corners for economic efficiency while providing enhanced chip discharge capability at critical locations through the larger second clearance angle.
2Manufacturing precision
If the space between the flank and the finished surface is small, then the cutting insert can process work materials with tight tolerances, but chips get caught in the space and discharge performance deteriorates
Solution Approach 1:
The patent applies parameter changes by varying the clearance angle parameter across different circumferential side surfaces. The first circumferential side surface has a first clearance angle and the second circumferential side surface has a second clearance angle that is explicitly designed to be larger. This parameter variation allows the cutting insert to maintain tight tolerance control in some areas while providing sufficient chip discharge space in critical areas where the larger clearance angle creates more room between the flank and the finished surface.
Data Source
AI summary
Provided is a cutting insert, which has excellent chip discharge performance even when formed with multiple corners superior in economic efficiency. A first ridgeline at which an upper surface and a circumferential side surface intersect each other includes a plurality of corners disposed at equal intervals and a plurality of main cutting edges disposed one by one between the corners adjacent to each other. A distance between the corners adjacent to each other is equal to or less than 60% of the diameter of a circle inscribed within the ridgeline. The main cutting edges includes a first cutting edge that is linearly formed and a second cutting edge that is linearly formed. The length of the second cutting edge is equal to or less than half the length of the first cutting edge and is positioned closer to a center side of the cutting insert than an extension line of the first cutting edge is. The circumferential side surface includes a first side surface facing the first cutting edge and a second side surface facing the second cutting edge. A clearance angle of the first side surface is smaller than that of the second side surface.