Negative Cutting Insert With Tangential Chamfer
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Negative cutting inserts for machining operations face issues with wear and vibrations, leading to reduced accuracy and shorter tool life, as well as increased noise and surface roughness due to uneven wear patterns and reaction forces during turning and milling operations.
Innovation Solution
The introduction of a chamfer extending from the cutting edge to the clearance side, making an angle of 1°-10° or 3°-8°, which reduces vibrations and flank wear, allowing for longer tool life and improved machining accuracy by applying the insert tangentially to the workpiece, and optionally incorporating a convex wiper edge and boron nitride material for enhanced performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rounded part is provided to improve wear resistance and suppress breaking, then the wear resistance of the clearance side is improved, but vibrations and noise during machining increase
Solution Approach 1:
The invention changes the geometric parameters of the clearance side by introducing a chamfer with specific angle (1°-10° or 3°-8°) and extension length (0.03mm-0.30mm), replacing the conventional rounded part design. This parameter change modifies the contact mechanics between the insert and workpiece, reducing vibrations and noise while maintaining wear resistance.
Solution Approach 2:
The chamfer is applied locally at specific regions of the clearance side rather than uniformly rounding the entire edge. This localized modification allows the insert to maintain structural integrity and wear resistance in critical areas while reducing harmful vibrations and noise through the chamfered surfaces.
2Productivity
If the insert is used for extended periods to reduce disposal costs, then productivity is improved, but machining accuracy deteriorates due to flank wear
Solution Approach 1:
The chamfer geometry parameters (angle and extension length) are optimized to control the wear pattern on the clearance side. This parameter optimization allows the insert to maintain acceptable flank wear levels for extended periods while preserving machining accuracy within tolerance ranges.
Solution Approach 2:
The chamfer is pre-formed on the insert before machining operations begin. This preliminary geometric feature prepares the insert to distribute contact stresses and control wear progression from the outset, enabling extended tool life while maintaining accuracy throughout the tool's service life.
3Object-generated harmful factors
If a larger chamfer extension is used to further reduce vibrations, then vibrations are reduced, but the machining region and productivity are reduced
Solution Approach 1:
The chamfer extension length is optimized within a specific range (0.03mm-0.30mm) to achieve the best balance between vibration reduction and maintaining adequate machining region. This parameter optimization ensures that the chamfer is sufficient to reduce vibrations and noise while not excessively reducing the active cutting area and productivity.
Data Source
Figure 1~6
Figure 7~8
AI summary
A negative insert (1) f o r cutting machining h a s a top side (6), a clearance side (7) perpendicular thereto and a cutting edge (8) in a 5 region interconnecting these sides and extending substantially in p a r a l l e l with t h e s e sides. The insert has further a flat or rounded chamfer (10) connecting said cutting edge to said clearance side on at least one lateral side of the insert in the region of a corner thereof. The chamfer makes an angle of 1°-15° with the clearance side for 10 enabling application of the chamfer substantially tangentially to a w o r k piece (12) to be machined for bearing of the insert in two d i - m e n s i o n s against said work piece during cutting machining o p e r a t i o n carried out by the insert. ( F i g 5). 15