Segmented Chip Breaker Geometry for Cutting Insert Chip Control
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Solution Overview
Problem
Conventional cutting tools face difficulties in adequately controlling chips, particularly when the depth of cut is increased, leading to improper chip breaking.
Innovation Solution
The cutting tool features a cutting edge member with a concave first wall surface, convex second and third wall surfaces, and a fourth wall surface with a smaller height, arranged to effectively manage chip flow and breaking, including a breaker bottom surface and connection surfaces, which are designed to protrude and depress in specific directions to enhance chip control across varying cutting depths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional chip breaker with a single convex surface is used, then chip control is improved under certain conditions, but chip breaking becomes inadequate when depth of cut is increased
Solution Approach 1:
The chip breaker wall surface is segmented into multiple distinct surfaces (first wall surface with concave surface, second wall surface with convex surface, third wall surface with convex surface, and fourth wall surface with convex surface). Each surface is positioned at different locations relative to the imaginary plane and serves specific chip control functions, enabling effective chip breaking across various depth of cut conditions that a single surface cannot achieve
Solution Approach 2:
Different regions of the chip breaker are given different geometric properties: the first wall surface has a concave surface depressed toward the rear, while the second, third, and fourth wall surfaces have convex surfaces protruding toward the front. Each surface has specific height relationships (the fourth wall surface has smaller height than the second and third wall surfaces), creating localized functional zones that address different chip control needs depending on cutting depth
2Productivity
If the depth of cut is increased, then material removal rate is improved, but chip control deteriorates
Solution Approach 1:
The chip breaker design extends chip control into multiple spatial dimensions by positioning wall surfaces at different distances from the imaginary plane (spaced apart positions) and creating varying heights in the vertical dimension (fourth wall surface has smaller height than second and third wall surfaces). This multi-dimensional configuration allows the chip breaker to effectively manage chips generated at increased depths of cut while maintaining productivity
Data Source
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AI summary
There is provided a cutting tool (100) in which chip control is improved. A cutting edge member (20) includes a first wall surface (20B1) which includes a concave surface which is formed to be depressed in a direction away from an intersection point (P) of an imaginary plane (IP) and a corner portion (20C1) and toward the center (AX) of a cutting insert (10) in an end view when viewed from a direction facing an end surface (20U), a second wall surface (20B2) which includes a convex surface which is provided to be connected to the first wall surface at a position spaced apart from the imaginary plane and is protruded in a direction away from the center of the cutting insert in the end view, a third wall surface (20B3) which includes a convex surface which is provided to be connected to the first wall surface at a position spaced apart from the imaginary plane on an opposite side to the second wall surface across the imaginary plane and is protruded in a direction away from the center of the cutting insert in the end view, and a fourth wall surface (20B4) which is provided in an area between the first wall surface and the intersection point in the end view, includes a convex surface which is protruded in a direction away from the center of the cutting insert in the end view, and has a height smaller than heights of the second wall surface and the third wall surface in a side view when viewed from a direction facing a side surface (20S).