Segmented Cutting Insert Edge Geometry for Hardened Steel Machining
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Solution Overview
Problem
High cutting resistance during high-efficiency processing of hardened steel leads to frequent breakage of cutting edges, reducing the tool life of cutting inserts.
Innovation Solution
A cutting insert with specific edge configurations, including curved and straight cutting edge portions made of cBN-based, diamond-based, ceramic, or cemented carbide materials, optimized with curvature radii and angles 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 portion, third high cut-in pulling portion, and fourth finished-surface portion) along the cutting width direction. Each portion has specific geometric characteristics optimized for different cutting functions, allowing the tool to handle various cutting conditions simultaneously and reduce overall cutting resistance while maintaining productivity
Solution Approach 2:
Different portions of the cutting edge are given different local geometric properties: the corner processing portion has specific curvature radius for corner engagement, the low cut-in pulling portion has optimized curvature for gentle material engagement, the high cut-in pulling portion has geometry for aggressive material removal, and the finished-surface portion has specific curvature for surface quality. This local optimization allows each portion to perform its specific function efficiently, reducing overall cutting resistance while maintaining high productivity
2Stability of the object's composition
If cutting edge curvature radius is increased for stability, then cutting stability is improved, but manufacturing precision may be affected
Solution Approach 1:
The cutting edge is segmented into multiple portions with different curvature radius requirements. The corner processing portion has curvature radius of 0.1mm or more and 2.4mm or less for stability during corner engagement, while the finished-surface portion has curvature radius of 3mm or more for stability during finishing. This segmentation allows each portion to have optimized curvature for its specific function without compromising overall manufacturing precision
Solution Approach 2:
Each cutting edge portion has locally optimized curvature radius: the first cutting edge portion (corner processing) has curvature radius of 0.1-2.4mm for stable corner engagement, the second cutting edge portion (low cut-in pulling) has curvature radius of 3mm or more for stable gentle cutting, and the fourth cutting edge portion (finished-surface) has curvature radius of 3mm or more for stable finishing. This local quality optimization ensures cutting stability at each position while maintaining overall manufacturing precision through the coordinated design of all portions
Data Source
AI summary
A cutting insert includes a rake face, a flank face, and a cutting edge constituted of a ridgeline between the rake face and the flank face. The cutting edge has a first cutting edge portion for corner processing, a second cutting edge portion for low cut-in pulling processing, a third cutting edge portion for high cut-in pulling processing, a fourth cutting edge portion 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.