Segmented Cutting Insert with Inclined Grooves for Chip Control
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Solution Overview
Problem
Conventional cutting inserts face challenges in reducing cutting resistance and achieving efficient chip discharging, leading to potential damage to the workpiece and cutting tool due to clogged chips.
Innovation Solution
A cutting insert with a main body featuring a groove on its side surface that extends to the upper surface, dividing the cutting edge into multiple segments, and inclined parts on the upper surface to provide additional rigidity to narrow chips, allowing for effective curling and discharge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the number of grooves is increased to reduce cutting resistance, then the cutting resistance is reduced, but the chips become too narrow and fail to curl properly, causing chip clogging
Solution Approach 1:
The cutting edge is divided into multiple divided cutting edges by grooves, which segments the chip into narrower portions. This segmentation reduces cutting resistance while the controlled segmentation allows proper chip curling through the inclined parts.
Solution Approach 2:
Inclined parts are added at specific locations on the upper surface corresponding to each divided cutting edge. These inclined parts provide localized chip compression and curling assistance only where needed, allowing narrow chips to curl properly without requiring fewer grooves.
2Force
If the cutting edge is divided into more segments, then the chip width is reduced and cutting resistance decreases, but the chip rigidity becomes insufficient for proper curling
Solution Approach 1:
Inclined parts are strategically positioned at specific locations on the upper surface to provide localized chip compression and curling assistance. This local reinforcement of chip rigidity occurs only where needed, allowing narrow chips to curl properly without sacrificing the benefits of extensive groove segmentation.
Solution Approach 2:
The inclined parts are positioned to act on the chip before it fully forms, providing preliminary compression and guiding the chip into a proper curling path. This preliminary action ensures that even narrow chips with insufficient inherent rigidity can curl correctly.
Data Source
AI summary
A cutting insert has a main body which is provided with an upper surface, a side surface, at least one groove which is formed in the side surface and which extends to the upper surface at one end, and a plurality of split cutting blades which are split by the at least one groove. The upper surface is provided with inclined portions corresponding to the split cutting blades. The distance of respective lower ends of the inclined portions from the corresponding split cutting blades increases toward the centers of the corresponding cutting blades in a plan view. A cutting tool having the cutting insert and a method for cutting a workpiece using the cutting tool are also provided.