Cutting Insert Edge Geometry With Split Angles and Curved Transition
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Solution Overview
Problem
Conventional cutting inserts face a challenge in achieving both high cutting performance and edge strength, as increasing the intersection angle of the main cutting edge enhances edge strength but may decrease cutting performance, while decreasing the angle improves cutting performance at the cost of reduced edge strength.
Innovation Solution
A cutting insert design featuring a main cutting edge with first and second straight portions and a curved portion, where the intersection angles of these portions with respect to a reference side are different, allowing for adjustable shape and reduced stress concentration, thereby enhancing both cutting performance and edge strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the intersection angle of the main cutting edge is increased to enhance edge strength, then the edge strength is improved, but the cutting performance (sharpness) deteriorates
Solution Approach 1:
The main cutting edge is divided into multiple segments with different intersection angles. The first main cutting edge has a first intersection angle optimized for edge strength, while the second main cutting edge has a second intersection angle optimized for cutting performance. This segmentation allows each edge to perform its specialized function without compromising the other.
Solution Approach 2:
Different portions of the cutting insert are given different local properties through varying intersection angles. The first main cutting edge portion is designed with a larger intersection angle for strength in high-stress areas, while the second main cutting edge portion has a smaller intersection angle for sharper cutting action in areas where strength is less critical.
2Productivity
If the intersection angle of the main cutting edge is decreased to improve cutting performance, then the cutting performance is improved, but the edge strength deteriorates
Solution Approach 1:
The cutting insert features multiple main cutting edges with different intersection angles, allowing the system to provide both high-strength cutting (first main cutting edge) and high-performance cutting (second main cutting edge) capabilities simultaneously.
Solution Approach 2:
The cutting insert employs asymmetric design with non-uniform intersection angles across different main cutting edges. This asymmetry enables optimization for different cutting conditions and orientations, providing both strength and performance in appropriate locations.
3Device complexity
If a single intersection angle is used for the main cutting edge, then the design is simple, but both edge strength and cutting performance cannot be simultaneously optimized
Solution Approach 1:
Rather than using a single compromised intersection angle, the cutting edge is segmented into multiple portions with different angles, allowing simultaneous optimization for both strength and performance without significantly increasing overall design complexity.
Solution Approach 2:
The intersection angle parameter is varied across different main cutting edges to optimize performance. By changing this geometric parameter in different locations, the design achieves both high strength and high cutting performance without requiring fundamentally different designs.
Data Source
AI summary
A cutting insert includes a main body including a first face, a second face, and a third face. The second face includes a rake face. Among the outer-peripheral sides of the second face, the boundary portion with the first face is a main cutting edge. When viewed from the side where the first face is disposed, the main cutting edge includes a first straight portion, a second straight portion, and a curved portion. The first straight portion is located adjacent to a reference side. The second straight portion is arranged at a distance from the first straight portion. The curved portion connects the first straight portion and the second straight portion. A first intersection angle of the first straight portion with respect to the reference side is different from a second intersection angle of the second straight portion with respect to the reference side.