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 depths of cut, leading to chip entrapment between the workpiece and milling tool, resulting in surface 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, depths, and shapes to enhance chip evacuation, along with 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 adding a groove that divides the surface into distinct regions. This segmentation creates a chip evacuation path that separates chips from the cutting zone, preventing chip entrapment between the workpiece and tool 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, guiding chips away from the workpiece surface without interfering with the cutting edge's ability to withstand and remove material under load.
2Strength
If chips are not properly evacuated, then the cutting insert maintains structural integrity, but heat generation increases and wear accelerates
Solution Approach 1:
The groove segments the corner rake surface to create a thermal management pathway. By dividing the rake surface, the groove allows heat generated at the cutting edge to be conducted away through the groove walls, reducing heat accumulation in the insert while maintaining overall structural integrity.
Solution Approach 2:
The groove extracts heat from the cutting zone by providing a thermal conduction path through its walls. This extraction of thermal energy prevents excessive heat buildup that would otherwise lead to increased wear and potential insert failure, while the groove's design maintains the insert's structural strength.
Data Source
Figure 1
Figure 2~3
Figure 4~4b
AI summary
A double-sided tangential cutting insert 21, comprising: two identical opposing end surfaces 25; a peripheral side surface 29 extending between the opposing end surfaces 25, the peripheral side surface 29 comprising two opposing identical major side surfaces 31, two opposing identical minor side surfaces 49 and four corner surfaces 61, each corner surface 61 inter-connecting a major side surface 31 and an adjacent minor side surface 49; a hole 35 extending through the insert 21 from one of the major side surfaces 31 to the other of the major side surfaces 31; each of said end surfaces 25 comprising: two spaced apart major cutting edges 33, each major cutting edge being formed at an intersection between the end surface 25 and one of the major side surfaces 31; two spaced apart minor cutting edges 51, each minor cutting edge being formed at an intersection between the end surface 25 and one of the minor side surfaces 49; two diagonally opposite raised corners 26, each raised corner 26 having a corner cutting edge 63c, each corner cutting edge 63c being formed at an intersection between the end surface 25 and one of the corner surfaces 61, each corner cutting edge 63c positioned between a major cutting edge 33 and a minor cutting edge 51; two diagonally opposite lowered corners 27, each lowered corner 27 having a corner non-cutting edge 63nc, each corner non-cutting edge 63nc being formed at an intersection between the end surface 25 and one of the corner surfaces 61, each corner non-cutting edge 63nc positioned between a major cutting edge 33 and a minor cutting edge 51; major rake surfaces 37 adjacent the major cutting edges 31; minor rake surfaces 53 adjacent the minor cutting edges 51; cutting corner rake surfaces 65c adjacent the corner cutting edges 63c; and non-cutting corner rake surfaces 65nc adjacent the non-cutting edges 63nc, wherein at least one cutting corner rake surface 65c comprises a groove 67 that extends in a generally inward direction.