Multi-Corner Cutting Insert for Burr and Chipping Control
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Solution Overview
Problem
Existing cutting inserts with multiple corners face challenges in inhibiting burr generation and chipping, especially when trying to maintain economical efficiency and complex edge shapes, as the space between corners becomes narrower, making it difficult to produce cutting edges with varying angles and curvatures effectively.
Innovation Solution
A cutting insert design featuring alternately disposed major cutting edges and wiper cutting edges, with deburring and corner cutting edges, where the distance between adjacent corners is 60% or less of the inscribed circle diameter, allowing for the same length of wiper cutting edges and the addition of deburring and corner cutting edges, which reduces burr height and chipping risk by providing sufficient space for chip discharge and curvature protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple corners are formed in the cutting insert to improve economical efficiency, then the number of usable edges increases, but the distance between adjacent corners becomes narrow, making it difficult to dispose both major cutting edges and wiper cutting edges between the corners
Solution Approach 1:
The cutting insert is divided into multiple corners (at least four corners) with multiple usable edges between adjacent corners. Each corner region is segmented to accommodate different types of cutting edges (major cutting edge and wiper cutting edge) independently, allowing efficient utilization of the insert while maintaining sufficient space for complex edge configurations
Solution Approach 2:
The cutting edges are arranged in a radial pattern from the center of the cutting insert outward to the ridgeline. This radial dimensionality allows multiple cutting edges to be disposed between corners without simply increasing linear distance, as edges can be positioned at different radial distances and angular positions, effectively utilizing the two-dimensional space between corners
2Productivity
If the distance between adjacent corners is reduced to maintain multi-corner configuration, then economical efficiency improves, but it becomes difficult to form cutting edges with varying angles and curvatures
Solution Approach 1:
Different regions of the cutting insert are designed with locally optimized cutting edge characteristics. Major cutting edges have specific angles for material removal, while wiper cutting edges have different angles for finishing. Each corner region is configured with appropriate edge types and geometries tailored to local functional requirements, allowing shape complexity to be maintained even with reduced corner distances
Solution Approach 2:
The cutting insert employs varying geometric parameters for different cutting edges, including cutting angles, curvature radii, and edge lengths. By changing these parameters locally for major versus wiper cutting edges, the design achieves complex edge shapes necessary for different machining functions while accommodating the constrained space between closely spaced corners
3Manufacturing precision
If wiper cutting edges are added to reduce burr height, then surface quality improves, but the space between corners becomes insufficient for accommodating both major and wiper cutting edges
Solution Approach 1:
Multiple cutting edge functions are merged into a single cutting insert by disposing both major cutting edges and wiper cutting edges between adjacent corners. The major cutting edge performs primary material removal while the wiper cutting edge performs finishing operations, combining粗加工 and 精加工 capabilities in one tool to reduce burrs without requiring additional tools or increasing corner spacing
Solution Approach 2:
The cutting insert is designed with multi-functionality by incorporating different types of cutting edges (major and wiper) that can perform different machining functions. The same insert can alternately use major cutting edges for roughing and wiper cutting edges for finishing, making the tool universal for multiple operations and eliminating the need for separate single-function inserts
4Manufacturing precision
If corners are made sharp for precise cutting, then cutting precision improves, but the cutting edge becomes susceptible to chipping
Solution Approach 1:
Different corner regions are designed with locally optimized geometries. Some corners have sharper configurations for precise cutting where needed, while other corners incorporate rounded profiles or chamfers to reduce stress concentration and prevent chipping. Each corner's geometry is tailored to its specific functional requirements and loading conditions
Data Source
AI summary
Provided is a cutting insert, within which a burr being generated at an outer edge of a finished surface is inhibited and chipping of the cutting insert is inhibited even when the cutting insert is formed to have multiple corners superior in economical efficiency. The cutting insert has an upper surface, a lower surface on an opposite side to the upper surface, and a circumferential side surface connecting the upper surface and the lower surface to each other. A first ridgeline at which the upper surface and the circumferential side surface intersect each other includes major cutting edges and wiper cutting edges which are alternately disposed one by one, and corners each disposed between each of the major cutting edges and each of the wiper cutting edges. A distance between the corners that are adjacent to each other is equal to or less than 60% of a diameter of an inscribed circle of the first ridgeline. The corner that is positioned at one end of the wiper cutting edge is formed at a deburring cutting edge that intersects the wiper cutting edge at an angle smaller than an angle formed by the major cutting edge and the wiper cutting edge. The corner that is positioned at the other end of the wiper cutting edge is formed at a corner cutting edge having a curvature larger than that of the wiper cutting edge.