Double-Sided Tangential Cutting Insert With Corner Chip-Guiding Grooves
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Solution Overview
Problem
Double-sided tangentially mounted cutting inserts face challenges with chip control, particularly at low depth of cut, leading to chip entrapment between the workpiece and milling tool, resulting in scratches and increased wear and heat generation.
Innovation Solution
The design incorporates inwardly directed grooves in corner rake surfaces to guide chips away from cutting edges, with specific angles and dimensions to ensure efficient chip evacuation, and includes support and transition surfaces for stable mounting and precise positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the insert is used in operations utilizing a low depth of cut, then the cutting insert can withstand greater cutting forces, but chips may get stuck between the work piece and the rotating milling tool leading to scratches
Solution Approach 1:
The corner rake surface is segmented by introducing a groove that divides the surface into distinct regions. This segmentation creates a chip evacuation path that separates the chip flow from the cutting edge area, preventing chip entrapment while maintaining the structural integrity of the insert for withstanding cutting forces.
Solution Approach 2:
The groove acts as an intermediary element between the cutting edge and the chip flow path. It provides a dedicated channel that mediates chip evacuation, preventing direct contact between chips and the workpiece surface, thus eliminating scratches while allowing the insert to maintain its strength.
2Temperature
If chips are not properly evacuated, then the cutting insert generates more heat and experiences increased wear, but adding chip evacuation features may reduce insert strength
Solution Approach 1:
The groove is introduced only in the corner rake surface region where chip evacuation is most critical, rather than modifying the entire insert structure. This localized modification provides effective chip evacuation and heat management while preserving the overall structural strength and rigidity of the insert body.
Data Source
AI summary
A double-sided tangential cutting insert includes two identical opposing end surfaces and a peripheral side surface extending between the end surfaces. The peripheral side surface has two opposing identical major side surfaces, two opposing identical minor side surfaces and four corner surfaces. Each of the end surfaces include two spaced major cutting edges formed at an intersection between the end surface and one of the major side surfaces, two spaced minor cutting edges formed at an intersection between the end surface and one of the minor side surfaces, two diagonally opposite raised corners, each with a corner cutting edge, two diagonally opposite lowered corners, each having a corner non-cutting edge, major rake surfaces adjacent the major cutting edges, minor rake surfaces adjacent the minor cutting edges, cutting corner rake surfaces adjacent the corner cutting edges, and non-cutting corner rake surfaces adjacent the non-cutting edges.