Undulating Cutting Insert Geometry for Grooving and Cross Feeding
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Solution Overview
Problem
Existing cutting inserts face poor chip control during cross feeding following grooving, leading to machining precision and efficiency issues due to chips lodging between the insert and work material.
Innovation Solution
A cutting insert with a substantially rectangular parallelepiped-shaped tip end portion featuring an upper face with a projection-shaped or groove-shaped first upper face portion and an undulating upper face portion, where the undulating shape on the upper face controls chip shape during cross feeding and the first upper face portion improves chip control during grooving.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional cutting insert with a flat upper face is used, then the structure is simple and easy to manufacture, but chip control during cross feeding is poor causing chips to lodge between the insert and work material
Solution Approach 1:
The patent applies curvature by forming an undulating upper face portion with multiple peaks and valleys instead of a flat surface. This undulating shape specifically controls chip flow during cross feeding operations, preventing chips from lodging between the insert and work material while maintaining manufacturing feasibility through standard forming processes
2Productivity
If the upper face is made flat and simple, then manufacturing is easier, but chip shape control during cross feeding is insufficient affecting machining precision and efficiency
Solution Approach 1:
The undulating upper face portion with its curved peaks and valleys actively controls chip shape and flow direction during cross feeding. This geometric feature improves machining efficiency by preventing chip lodging and facilitating smooth chip evacuation, while the curvature can be implemented through conventional forming methods
Solution Approach 2:
The patent applies different face geometries to different regions: a first upper face portion for grooving operations and an undulating upper face portion specifically for cross feeding operations. This localized differentiation optimizes chip control for each specific cutting operation without unnecessarily complicating the entire insert structure
Data Source
AI summary
A cutting insert exhibits superior chip control during grooving and cross feeding. Embodiments include a cutting insert having an upper face, a front face forming an intersecting ridgeline with the upper face, side faces connected to the front face forming intersecting ridgelines with the upper face, a front face cutting edge on the intersecting ridgeline between the upper face and the front face, and side cutting edges on the intersecting ridgelines between the upper face and the side faces. The upper face includes a first portion and an undulating portion on which peaks and troughs are formed continuously in a direction heading away from the front face cutting edge, the undulating portion provided on both lateral direction sides of the first portion. The undulating portion is configured such that the side cutting edges, when seen from the side, each have a continuous undulating shape from the front face cutting edge.