Thread Cutting Insert Chip Former Layout for Variable Chip Cross-Sections
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Solution Overview
Problem
Existing thread cutting inserts face challenges in efficiently cutting threads due to high cutting forces and ineffective chip evacuation, as the shape of chip formers is not adapted to the varying cross-section of chips encountered during the cutting process.
Innovation Solution
The design of thread cutting inserts with chip formers whose shape is adapted to the cross-section of chips encountered, considering the shape of both the preceding and subsequent cutting teeth, to facilitate better chip flow and reduce cutting forces by varying the distance between the cutting edge and the chip former based on chip thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a conventional chip former shape is used that does not adapt to varying chip cross-sections, then the device structure is simple, but chip evacuation is ineffective and cutting forces remain high
Solution Approach 1:
The chip former is designed with varying distance from the cutting edge along its length, creating different local geometries that correspond to the varying cross-section of chips at different positions. This local adaptation allows each segment of the chip former to optimally guide chips of specific thicknesses, improving overall chip evacuation efficiency without requiring a completely new device architecture
Solution Approach 2:
The distance parameter between the cutting edge and the chip former is systematically varied along the length of the chip former. This parameter change creates a gradient structure that matches the gradient in chip thickness, enabling effective chip flow control for varying chip cross-sections while maintaining a relatively simple overall structure
2Productivity
If the chip former is positioned at a constant distance from the cutting edge, then the structure is simple, but adequate space is not provided for chips with varying thickness
Solution Approach 1:
Different segments of the chip former are positioned at different distances from the cutting edge, creating locally optimized conditions for chip flow. Areas with thicker chips have chip formers positioned farther away to provide adequate space, while areas with thinner chips have chip formers positioned closer, achieving optimal chip guidance throughout the cutting process
Solution Approach 2:
The chip former geometry is designed to dynamically adapt to varying chip thicknesses through its non-uniform positioning. As chips of different thicknesses pass along the cutting path, the varying distance profile of the chip former automatically provides the appropriate clearance and guidance, effectively handling dynamic chip conditions without requiring active adjustment mechanisms
3Productivity
If cutting teeth produce varying chip cross-sections, then cutting action is effective, but chip evacuation becomes difficult without adapted chip formers
Solution Approach 1:
The chip former geometry is locally adapted to match the local chip cross-section characteristics produced by each cutting tooth. By varying the distance from the cutting edge at different positions along the chip former, the design creates a one-to-one correspondence between chip cross-section variations and chip former geometry, effectively guiding chips of all thicknesses without interfering with the cutting action
Solution Approach 2:
The varying chip cross-sections, which initially cause evacuation difficulties, are converted into a beneficial design parameter. The chip former is deliberately designed with varying distance profiles that transform the problem of variable chip thickness into an opportunity to create optimized flow paths for each chip segment, turning a harmful effect into a design advantage
Data Source
AI summary
A thread cutting insert for cutting threads includes a plurality of cutting teeth disposed along a cutting portion, each cutting tooth is provided with an allocated chip former, and the chip formers are provided on a rake face of the thread cutting insert. The shape of at least two cutting teeth is different from each other. At least one cutting tooth along the cutting portion is provided with an allocated chip former the shape of which is adapted to the shape of that cutting tooth which, with respect to an order of engagement during cutting operation, precedes the subsequent cutting tooth along the cutting portion such that the at least one chip former has a shape adapted to the cross-section of chips encountered by it. A set of at least two thread cutting inserts, a thread cutting tool and a method for cutting threads, are also provided.