Segmented Lateral Cutting Edge for Stable Chip Processing
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Solution Overview
Problem
Cutting inserts with inclined lateral cutting edges face issues of insufficient holder rigidity leading to chatter vibration and chip jamming due to uneven force distribution, particularly when processing thin or thick chips.
Innovation Solution
A cutting insert design featuring a lateral cutting edge with distinct regions of varying angles of inclination, where the first region has a relatively small angle and the second region has a larger angle, allowing for stable chip processing and reduced chatter vibration across different machining conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the lateral cutting edge is inclined with a large angle to disperse forces to the rear side, then holder rigidity is improved and chatter vibration is reduced, but chip pushing back force increases causing chip jamming
Solution Approach 1:
The lateral cutting edge is divided into multiple regions with different inclination angles. The first region has a smaller inclination angle to reduce chip pushing back force, while the second region has a larger inclination angle to disperse forces to the rear side and improve holder rigidity. This segmentation allows each region to fulfill different functional requirements simultaneously.
Solution Approach 2:
Different portions of the lateral cutting edge are assigned different local properties (inclination angles) according to their specific functional needs. The front portion (first region) has a smaller angle suitable for thin chip processing, while the rear portion (second region) has a larger angle suitable for force dispersion and holder stability.
2Reliability
If the lateral cutting edge is inclined to improve holder stability, then cutting insert stability is improved, but force distribution becomes uneven causing vibration
Solution Approach 1:
The lateral cutting edge is segmented into multiple regions with progressively different inclination angles. This segmentation enables the cutting edge to provide both stability through force dispersion and uniform force distribution by varying the angle across different regions, preventing concentration of forces that cause vibration.
3Ease of operation
If the holder width is narrowed to avoid interference during grooving, then interference is avoided, but holder rigidity becomes insufficient causing chatter vibration
Solution Approach 1:
Instead of increasing holder width to improve rigidity (which would cause interference), the solution inverts the approach by designing the cutting insert's lateral cutting edge with specific inclination angles that actively disperse forces away from the holder, thereby achieving rigidity improvement without increasing holder dimensions.
Data Source
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AI summary
A cutting insert of one aspect includes a main body section and a cutting section located in front of the main body section. The cutting section includes a front cutting edge disposed along a ridge line of the cutting section at an intersection between a top surface and a first side surface; and a lateral cutting edge disposed along the ridge line at an intersection between the top surface and a second side surface and inclined with ascending as getting away from the front cutting edge. The lateral cutting edge each includes a first region and a second region located to a rear of the first region; and an angle of inclination of the second region with respect to the bottom surface is larger than an angle of inclination of the first region with respect to the bottom surface.