Rotary Cutting Insert Recess Geometry for Swarf and Vibration Control
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Solution Overview
Problem
Conventional rotary cutting tools generate long, continuous swarf that damages finished surfaces due to the lack of a swarf breaker, leading to increased cutting resistance, vibration, and rough cut surfaces.
Innovation Solution
A rotary cutting tool insert with an annular rake face featuring recess portions that divide swarf into shorter lengths by curving it without contact with the inner surface, reducing friction and maintaining strength, thereby minimizing vibration and surface roughness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional cutting tool is used without a breaker, then the cutting process is simple, but long continuous swarf is generated that damages the finished surface
Solution Approach 1:
The invention introduces a breaker structure that segments the continuous swarf into shorter pieces. The breaker divides the swarf formation process into multiple segments, preventing long continuous swarf from forming and wrapping around the workpiece, thereby eliminating surface damage while maintaining manufacturing simplicity.
Solution Approach 2:
The breaker acts as an intermediary element between the cutting edge and the swarf. It mediates the swarf formation process by controlling and directing the swarf path, preventing direct contact between long swarf and the finished surface, thus protecting the surface without complicating the overall tool design.
2Ease of operation
If a breaker is added to cut swarf into short pieces, then swarf handling is improved, but cutting resistance and vibration increase
Solution Approach 1:
The breaker is designed with specific local geometric properties (angle, height, position) that optimize its swarf-cutting function while minimizing interference with the cutting process. By carefully controlling the local quality of the breaker structure, it effectively cuts swarf into manageable pieces without significantly increasing cutting resistance or vibration.
3Productivity
If the breaker is positioned closer to the cutting edge, then swarf is cut more effectively, but the breaker strength decreases
Solution Approach 1:
The invention optimizes the breaker's geometric parameters (height, angle, distance from cutting edge) to achieve the best balance between swarf cutting effectiveness and structural strength. By carefully selecting these parameters, the breaker can effectively cut swarf while maintaining sufficient strength to withstand cutting forces without breaking.
Data Source
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AI summary
A rotary cutting tool insert according to one embodiment of the present invention includes: an annular rake face (21) provided with at least one recess portion (23); and a cutting edge (22) formed at an outer circumference of the rake face, the recess portion having a width (B) of more than or equal to 1.2 mm and less than or equal to 3.0 mm in a circumferential direction of the rake face, a distance (LI) between the cutting edge and an end of the recess portion at the outer circumference side of the rake face being more than or equal to 0.1 mm and less than or equal to 0.5 mm. According to the rotary cutting tool insert according to the one embodiment of the present invention, roughness of a processed surface and vibration due to a cutting process can be prevented.