Segmented Cutting Insert Geometry for Stable Chip Flow
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Solution Overview
Problem
Existing cutting inserts face challenges in achieving effective chip discharge during both low-cutting depth and high-cutting depth machining due to large inclination angles of upright wall surfaces, leading to unstable chip flow and potential clogging.
Innovation Solution
The cutting insert design features a polygonal shape with specific inclination angles and a protruded part to facilitate chip curling and discharge, ensuring stable chip flow in both low-cutting depth and high-cutting depth machining by optimizing the intersection of surfaces and angles for enhanced durability and chip management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If large inclination angles of upright wall surfaces are used in cutting inserts, then chip discharge becomes difficult, but reducing inclination angles may affect structural stability
Solution Approach 1:
The upright wall surface is divided into multiple segments with different inclination angles (first upright wall surface with smaller angle, second upright wall surface with larger angle). This segmentation allows each segment to perform different functions: the first segment facilitates chip discharge while the second segment maintains structural stability, thereby resolving the contradiction between ease of operation and reliability.
Solution Approach 2:
Different regions of the upright wall surface are assigned different inclination angles based on local functional requirements. The region closer to the cutting edge has a smaller inclination angle to facilitate chip discharge, while regions further away have larger inclination angles to maintain structural stability. This local differentiation resolves the contradiction by optimizing each local area for its specific function.
2Reliability
If complex multi-surface geometry with multiple inclination angles is implemented, then chip flow stability improves, but manufacturing complexity increases
Solution Approach 1:
The complex geometry is segmented into a finite number of standardized surfaces (first inclined surface, second inclined surface, third inclined surface, fourth inclined surface, protruded part) with defined inclination angles. This segmentation makes the complex geometry manufacturable by breaking it down into discrete, repeatable features that can be produced using standard manufacturing processes.
Solution Approach 2:
The design uses specific parameter ranges for inclination angles (first inclination angle, second inclination angle, third inclination angle, fourth inclination angle) to achieve stable chip flow. By defining these parameters within specific ranges rather than arbitrary values, the patent balances manufacturing feasibility with performance requirements, resolving the contradiction between reliability and device complexity.
Data Source
AI summary
A cutting insert may include a first surface, a second surface, a third surface and a cutting edge. The first surface may include a corner, a first side, a first inclined surface located along the corner, a second inclined surface located further inside than the first inclined surface, a third inclined surface located along the first side, a fourth inclined surface located further inside the first surface than the third inclined surface, and a protruded part located further inside than the second inclined surface and the fourth inclined surface. An inclination angle of the protruded part may be smaller than an inclination angle of the second inclined surface in a cross section along a bisector of the corner. The inclination angle of the protruded part may be larger than a third inclination angle in a cross section orthogonal to the first side.