Segmented Chip Breaker Insert for Cooling Jet Access
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Solution Overview
Problem
Existing cutting inserts face challenges in dry machining and high-pressure cooling due to difficulties in chip removal, leading to high temperatures, reduced service life, increased costs, and high cutting forces, especially at flat angles.
Innovation Solution
A cutting insert with a polygonal shape and a chip-breaker arrangement comprising two symmetrically or asymmetrically positioned chip-breaker segments that allow for efficient chip lifting and high-pressure cooling, featuring recesses to facilitate jet direction and reduce pressure requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a boss near the nose-cutting edge is used to form and lead chip flow, then chip control is improved, but accessibility for high-pressure jet cooling is reduced
Solution Approach 1:
The chip breaker is divided into multiple segments (first chip breaker segment and second chip breaker segment) that are positioned at different locations and angles. This segmentation allows the jet to access the cutting zone from below while the segments collectively perform chip formation and control functions, resolving the conflict between chip control and jet accessibility.
2Ease of operation
If entirely planar cutting plates without chip breakers are used, then jet accessibility is improved, but temperatures increase and service life decreases
Solution Approach 1:
Instead of using a single planar surface or a continuous chip breaker, the invention employs multiple segmented chip breakers positioned at different locations. This allows the jet to flow underneath and cool the cutting insert effectively while the distributed segments provide sufficient chip control to manage temperatures and extend service life.
3Productivity
If very high pressures are used to lift chips, then chip removal is improved, but costs increase and temperatures rise
Solution Approach 1:
The segmented chip breaker arrangement creates multiple pathways and zones for chip control, allowing the jet to access the cutting zone more effectively at lower pressures. The segments are positioned to guide chips away from the cutting zone while permitting jet flow underneath, reducing the pressure required for effective chip removal and lowering operational costs.
4Ease of operation
If planar cutting inserts are used, then jet accessibility is improved, but cutting forces increase
Solution Approach 1:
The multiple chip breaker segments are positioned to provide progressive chip control and guidance. The first segment is positioned closer to the cutting edge while the second segment is positioned further away, creating a staged chip control system that reduces cutting forces while maintaining jet accessibility underneath the insert structure.
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
The solution extends the service life of cutting inserts, reduces cutting forces, and enables controlled chip forming, allowing for effective operation in both dry machining and high-pressure cooling environments with lower pressure usage, thus reducing costs and improving machining efficiency.
Implementation Method 1
lift the chip by means of a high-pressure jet... machining in combination with high-pressure cooling
Data Source
Figure 1A
Figure 1B~1D
Figure 1C
AI summary
The present invention relates to a cutting insert for turning. The cutting insert (10) comprises a polygonal body of a hard, wear-resistant material, which has an upper surface (12) and a lower surface, and a plurality of edge surfaces (13,14) uniting said surfaces. At least one chip-breaker arrangement (22) is provided in at least one of the lower and upper surfaces. At least one rounded cutting corner (11 ), provided with a nose-cutting edge (19), is formed at a nose portion (21 ) at the area of the intersection area of two edge surfaces. Said cutting corner defines a bisector (B). The chip-breaker arrangement (22) comprises two elongate chip-breaker segments (22A.22B) having an opening (24) provided therebetween intended to give room for a cooling jet directed toward said opening (24).