Recessed Cutting Insert Wall Structure for Feed-Range Chip Control
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Solution Overview
Problem
Conventional cutting inserts face challenges in chip discharge during high-feed and low-feed operations, particularly in high-depth-of-cut conditions, with limited freedom of feed and insufficient chip control, especially during low-feed machining.
Innovation Solution
A cutting insert with a prismatic shape featuring a front cutting edge, side cutting edge, recessed part, wavy wall surface, and discrete wall surface is designed, where the wavy wall surface lifts thick chips during high-feed operations and deforms thin chips during low-feed operations to improve chip discharge and control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a projection for chip control is formed on a rake surface of a cutting tool main body, then chip control is improved, but the distance between cutting point and projecting portion depends on sintered body size, limiting dimensions and cutting edge length
Solution Approach 1:
The invention transitions from a two-dimensional flat rake surface to a three-dimensional recessed structure with multiple levels. The recessed part creates vertical dimension changes that allow chip control surfaces to act on chips at different depths, enabling effective chip control in both low depth cutting and low-feed operations without being constrained by sintered body size.
Solution Approach 2:
The rake surface is segmented into multiple functional zones: a first rake surface, a second rake surface, and a third rake surface arranged at different positions and angles. This segmentation allows each surface to handle specific chip control functions, providing comprehensive chip control across various cutting conditions including low depth cutting and low-feed operation.
2Ease of manufacture
If the sintered body has a flat upper surface, then manufacturing is simple, but chips cannot be controlled during low depth cutting or low-feed operation
Solution Approach 1:
The recessed part is pre-formed in the cutting edge body before brazing to the substrate. This preliminary formation of the recessed structure eliminates the need for post-brazing machining or complex assembly, maintaining manufacturing simplicity while enabling effective chip control during low depth cutting and low-feed operation.
3Ease of operation
If an indented chip breaker is disposed in parallel to the side cutting edge, then chip control is provided, but adaptability to low-feed machining (finishing) is insufficient
Solution Approach 1:
The invention creates dynamic chip control through the interaction between the recessed part geometry and varying feed rates. The third rake surface with specific angle and position dynamically adapts to low-feed conditions, providing effective chip control during finishing operations where traditional parallel chip breakers fail.
Solution Approach 2:
Different regions of the cutting insert are given different functional qualities: the first rake surface for general cutting, the second rake surface for chip control, and the third rake surface specifically positioned and angled to provide enhanced chip control during low-feed machining operations, ensuring adaptability to finishing conditions.
Data Source
AI summary
Chip discharge during high-feed machining and low-feed machining particularly in a high-depth-of-cut state or the like is improved so as to allow so-called freedom of feed during cutting to be improved. A cutting edge body of a cutting insert includes a front cutting edge formed on one end side in a longitudinal direction, the front cutting edge being a cutting edge formed on an intersecting edge between a peripheral side surface and an upper surface of the cutting edge body having a prismatic shape, a side cutting edge formed on one end side in a lateral direction, a recessed part provided in the upper surface of the cutting edge body to be subsequent to the side cutting edge in the lateral direction, and a wall part having a wavy wall surface formed in a portion of the recessed part and a discrete wall surface formed at a position between the wavy wall surface and the side cutting edge and including a plurality of surfaces which are discrete along the longitudinal direction.