Recessed Corner Cutting Insert for Chip Flow Control
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Solution Overview
Problem
Existing cutting inserts lack effective chip flow control features, which are crucial for efficient metalworking operations as they impact energy consumption and machining efficiency.
Innovation Solution
A cutting insert design featuring a rake face with recessed corner cutting edges having a concave, conical, and cylindrical profile to guide chip flow, enhancing chip removal and reducing energy consumption during machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If conventional cutting insert design is used, then manufacturing is simpler, but chip flow control is insufficient leading to higher energy consumption
Solution Approach 1:
The cutting insert applies local quality by creating recesses specifically at the corner regions where cutting edges intersect, while leaving other areas of the rake face unchanged. This localized modification focuses chip flow control efforts where it is most needed without unnecessarily complicating the entire insert structure
Solution Approach 2:
The recesses are formed with curved, concave surfaces that guide chips smoothly away from the cutting zone. The curved geometry of the recesses creates beneficial chip flow patterns that reduce energy consumption compared to flat or angular surfaces
2Productivity
If cutting insert without recesses is used, then manufacturing is easier, but chip flow control is poor affecting machining efficiency
Solution Approach 1:
The invention changes the geometric parameters of the rake face by introducing recesses with specific dimensions, depths, and curvatures. These parameter modifications optimize chip flow characteristics to improve machining efficiency while the recesses can be manufactured using standard machining or forming processes
3Reliability
If cutting insert with recessed corners is used, then chip flow control is improved, but manufacturing precision requirements increase
Solution Approach 1:
The recesses can be segmented into different zones (e.g., deeper near the cutting edge, shallower toward the center) with varying geometries optimized for different functions. This segmentation allows each zone to be manufactured with appropriate precision levels and can be achieved through multi-step machining or forming processes
Data Source
Figure 1
Figure 2A~2B
Figure 3
AI summary
The present invention is directed to a cutting insert (10) with a rake face (20), a seating surface (25) and a plurality of flank faces (30a-30d) extending between the rake face and the seating surface. The intersection of the rake face and the plurality of flank faces define a plurality of cutting edges (35a-35d). The rake face (20) of the insert (10) has a plurality of corner regions (40a-40d) formed at the intersection of side cutting edges (35a 35d) to define corner cutting edges (45a-45d). The corner cutting edge (45a-45d) in at least one corner region (40a-40d) has a recessed profile (50a) when viewed from the side of the insert. The recessed profile (50a) has a concave shape and extends inwardly from the cutting edge (45a). At the cutting edge, the recess has a conical shape to define a conical portion (55a) and further inward from the cutting edge the recess may have a cylindrical shape to define a cylindrical portion (60a).