Rake-Surface Grooved Cutting Insert for Edge Cooling Without Fracture
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Solution Overview
Problem
Existing cutting tools with coolant grooves on the rake surface face challenges in efficiently managing heat and friction during high-speed machining, leading to potential cutting edge fracture and increased cutting forces.
Innovation Solution
The insert features a base with a rake surface containing multiple grooves positioned away from the ridgeline at angles between 20-90°, with specific dimensions and spacings that enhance coolant flow and reduce friction, while maintaining a safe distance from the cutting edge to prevent fracture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If grooves are disposed on the rake surface to enhance cooling effect, then coolant flow is improved, but cutting edge fracture resistance deteriorates
Solution Approach 1:
The groove configuration is optimized with specific parameters (distance from ridgeline: 40-700 μm, width: 50-700 μm, depth: 20-700 μm, angle: 20-90°) to create different functional zones - grooves positioned away from the ridgeline provide cooling without compromising cutting edge strength, while maintaining appropriate spacing (50-700 μm) between grooves to balance cooling efficiency and structural integrity
Solution Approach 2:
By controlling the geometric parameters of grooves (position, size, spacing, orientation), the patent achieves optimal balance between cooling performance and cutting edge strength. The specific parameter ranges ensure that grooves are positioned to maximize coolant flow while maintaining sufficient material strength at the cutting edge
2Temperature
If multiple grooves are added to improve coolant distribution, then cooling efficiency is enhanced, but cutting forces increase
Solution Approach 1:
Grooves are strategically positioned away from the ridgeline and oriented at specific angles (20-90°) to channel coolant effectively to cooling zones without interfering with the cutting edge geometry, thereby reducing friction and cutting forces while improving cooling efficiency
Solution Approach 2:
The groove spacing (50-700 μm) and dimensions are optimized to provide sufficient coolant distribution without excessive groove density that would compromise structural integrity and increase cutting forces
3Temperature
If grooves are positioned closer to the ridgeline to maximize cooling, then coolant flow to cutting edge is improved, but cutting edge stability deteriorates
Solution Approach 1:
The patent specifies that grooves shall be positioned at a distance of 40-700 μm from the ridgeline, creating an optimized zone that provides sufficient coolant flow to the cutting edge while maintaining adequate material stability and preventing cutting edge fracture
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration results in reduced cutting forces, improved coolant distribution for enhanced cooling, and increased fracture resistance of the cutting edge, enabling high-speed machining with prolonged tool life.
Implementation Method 1
a plurality of grooves that serve as a flow path for the coolant are disposed on a rake surface of the insert
Implementation Method 2
the insert and the workpiece are cooled with a coolant during a machining process
Implementation Method 3
the insert is brought into contact with a workpiece in use at high speed, and the insert is therefore subjected to temperature rise
Data Source
AI summary
An insert includes a base which includes a first surface, a second surface connecting to the first surface, and a cutting edge located on at least a part of a ridgeline of the first surface and the second surface. The first surface includes a plurality of grooves located at a position away from the ridgeline and extended at an angle of 20-90° relative to the ridgeline. The grooves are away from the ridgeline in a range of 40-700 μm. A width W of the grooves is 50-700 μm, and a depth D of the grooves is 20-700 μm. Spacing S between the grooves adjacent to each other is 50-700 μm. A cutting tool includes a holder, which has a length extending from a first end to a second end and includes a pocket located on a side of the first end, and the insert is located in the pocket.