Variable Land-Angle Cutting Insert for Durability and Surface Quality
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Solution Overview
Problem
Cutting inserts with high hardness materials like PCD and cBN face challenges in balancing durability and cutting performance, as increasing the inclination angle of the land surface to enhance durability can degrade machinability and surface quality.
Innovation Solution
The cutting insert design features a land surface with varying inclination angles, where the angle is larger at the midportion for enhanced durability and smaller at the end portion for better cutting performance, allowing for a ridge line intersection that functions as multiple cutting edges, optimizing durability and performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the inclination angle of the land surface is increased to enhance durability, then the durability is improved, but the machinability and surface quality are degraded
Solution Approach 1:
The land surface is designed with different inclination angles in different regions: a first land surface with a larger inclination angle (30° to 60°) at the midportion for enhanced durability and load-bearing capacity, and a second land surface with a smaller inclination angle (5° to 25°) at the end portion for better cutting performance and surface quality. This local differentiation resolves the contradiction by optimizing each region for its specific function.
Solution Approach 2:
The land surface is segmented into multiple portions (first land surface and second land surface) with distinct inclination angles. The first land surface connects to the midportion of the corner and has a larger inclination angle, while the second land surface connects to the end portion and has a smaller inclination angle. This segmentation allows simultaneous optimization of durability and cutting performance.
2Reliability
If the inclination angle of the land surface is increased to enhance durability, then the durability is improved, but the cutting performance is degraded
Solution Approach 1:
Different regions of the land surface are assigned different inclination angles suitable for their specific functions. The first land surface at the midportion has a larger inclination angle (30° to 60°) for durability, while the second land surface at the end portion has a smaller inclination angle (5° to 25°) for optimal cutting performance, resolving the contradiction between durability and cutting performance.
Solution Approach 2:
The land surface is divided into segmented portions with different inclination characteristics. The first land surface portion provides structural durability, while the second land surface portion optimizes cutting performance, allowing both durability and productivity to be enhanced simultaneously.
Data Source
AI summary
A cutting insert may include a first surface, a second surface, a third surface, and a land surface. The first surface may include a first corner, a first side, and a second side. The land surface may be inclined relative to the first surface and the third surface. The land surface may include a first land surface connecting to the first corner. An imaginary flat surface orthogonal to a central axis connecting a center of the first surface and a center of the second surface may be a reference plane, a first inclination angle of a part of the first land surface which connects to a midportion of the first corner may be larger than a second inclination angle of a part of the first land surface which connects to an end portion at a side of the first side of the first corner.