Segmented Cutting Insert Edge for Hardened Steel Machining
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Solution Overview
Problem
High cutting resistance during high-efficiency processing of hardened steel leads to increased breakage of cutting edges, reducing the tool life of cutting inserts.
Innovation Solution
A cutting insert composed of cBN-based, diamond-based, ceramic, or cermet materials with specific edge configurations, including curved and straight cutting edge portions, connection edge portions, and controlled angles and radii, designed for improved durability and stability during various cutting operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high-efficiency processing for hardened steel is performed, then productivity is improved, but cutting resistance becomes high causing breakage of cutting edge
Solution Approach 1:
The cutting edge is divided into multiple distinct portions (first corner processing portion, second low cut-in pulling processing portion, third high cut-in pulling processing portion, and fourth finished-surface processing portion), each optimized for specific cutting conditions. This segmentation allows the tool to handle high productivity requirements while distributing stress across different edge sections, preventing catastrophic breakage.
Solution Approach 2:
Different portions of the cutting edge are given different local geometries and properties. The first portion has specific curvature for corner processing, while the second and third portions have different curvature radii (3mm or more) optimized for pulling processing. This local quality differentiation enables each section to optimally handle its specific function, improving overall reliability under high-efficiency conditions.
2Manufacturing precision
If cutting edge curvature radius is increased for pulling processing, then surface finish is improved, but cutting resistance increases
Solution Approach 1:
The cutting edge is segmented into multiple portions with different curvature radii. The second portion (low cut-in pulling) and third portion (high cut-in pulling) both have curvature radii of 3mm or more, optimized for surface finish. By distributing the cutting function across segmented portions rather than using a single large-radius edge, the patent manages cutting resistance while achieving quality surfaces.
Solution Approach 2:
The patent applies partial action by using multiple cutting edge portions with different geometries for different processing stages. Rather than using one excessive curvature radius for all operations, each portion is optimized for its specific function, balancing surface finish requirements with cutting force management.
Data Source
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AI summary
A cutting insert includes a rake face (50), a flank face (70), and a cutting edge (10) constituted of a ridgeline (20) between the rake face and the flank face. The cutting edge has a first cutting edge portion (1) for corner processing, a second cutting edge portion (2) for low cut-in pulling processing, a third cutting edge portion (3) for high cut-in pulling processing, a fourth cutting edge portion (4) for finished-surface processing, a first connection cutting edge portion, a second connection cutting edge portion, and a third connection cutting edge portion. The fourth cutting edge portion is disposed between the first cutting edge portion and the second cutting edge portion. The second cutting edge portion is disposed between the fourth cutting edge portion and the third cutting edge portion. Each of the first cutting edge portion, the second cutting edge portion, and the fourth cutting edge portion has a curved shape. A curvature radius of the first cutting edge portion is 0.1 mm or more and 2.4 mm or less. A curvature radius of the second cutting edge portion is 3 mm or more. A curvature radius of the fourth cutting edge portion is 3 mm or more. The third cutting edge portion has a straight line shape.