Throwaway Insert Edge Geometry for Chipping-Resistant Regrinding
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Solution Overview
Problem
The existing throwaway inserts with cutting edge members that cross at an acute angle suffer from low strength at the end portions, leading to chipping during grinding and limited reuse due to difficulty in increasing the number of grinding cycles.
Innovation Solution
A throwaway insert design with a cutting edge member that includes a rake face, flank face, and connecting faces forming ridgelines at obtuse angles, allowing for precise positioning and grinding without damaging the base, thereby enhancing the cutting edge's durability and reusability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the cutting edge member is designed with ridgelines crossing at an acute angle, then the cutting edge can be formed, but the strength at the end portions becomes low causing chipping during grinding
Solution Approach 1:
The patent changes the geometric parameter of the ridgeline crossing angle from acute to obtuse. This parameter modification fundamentally alters the stress distribution at the end portions of the cutting edge member, transforming the weak acute angle configuration into a strong obtuse angle configuration that resists chipping during grinding operations.
2Duration of action of moving object
If the cutting edge member is ground to remove damage, then the cutting edge can be restored, but the number of grinding cycles is limited due to the acute angle design
Solution Approach 1:
By changing the ridgeline crossing angle parameter from acute to obtuse, the patent extends the service life of the cutting edge member. The obtuse angle design provides a geometric foundation that allows multiple grinding cycles to be performed while maintaining structural integrity, thereby increasing the duration of action and enabling repeated reuse.
3Object-affected harmful factors
If the flank face and connecting face are positioned internal to the base, then the structure is compact, but the grinding process damages the base
Solution Approach 1:
The patent employs asymmetric positioning where the flank face and at least one connecting face are located external to the base rather than internal. This asymmetric configuration creates a spatial separation between the grinding zone and the base material, allowing the grinding wheel to access the cutting edge surfaces without interfering with or damaging the base structure.
4Productivity
If the cutting edge member is designed for high reusability, then productivity increases, but the cutting edge stability must be maintained
Solution Approach 1:
The patent modifies the geometric parameter of the ridgeline crossing angle to obtuse, which simultaneously achieves two objectives: it enhances cutting edge stability by creating a stronger structural configuration that resists deformation and chipping, and it enables high reusability by allowing multiple grinding cycles. This parameter change resolves the apparent contradiction between stability and reusability by making the cutting edge member both stable and reusable.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design enables a throwaway insert with improved cutting edge stability and extended reuse, maintaining cutting precision and performance by preventing chipping and chatter vibration during grinding.
Implementation Method 1
grinding the flank face of the cutting edge member using a grindstone while moving the grindstone relative to the cutting edge member
Data Source
AI summary
A throwaway insert includes a base and a cutting edge member. The cutting edge member includes: a rake face; a flank face extending to cross the rake face; a first connecting face connecting the flank face to a side surface of the base and extending to cross the rake face; and a first ridgeline formed by the rake face and the flank face and serving as a cutting edge. When viewed in a plan view from the upper surface of the base, the flank face and the first connecting face are located external to the base. A second ridgeline formed by the rake face and the first connecting face crosses the first ridgeline at an obtuse angle.