Wiper-Edge Cutting Insert for High-Feed Finishing
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Solution Overview
Problem
Conventional cutting inserts struggle to simultaneously achieve high-feed machining and finishing, as they often compromise on surface roughness and cutting resistance.
Innovation Solution
A cutting insert design featuring a major cutting edge, corner edge, and an outwardly-curved wiper edge with a specific angle and positive land, which reduces cutting resistance and improves surface finish.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a smaller cutting edge angle is used to achieve high-feed machining, then productivity is improved, but surface roughness deteriorates
Solution Approach 1:
The cutting edge is divided into three distinct segments: a major cutting edge for high-feed machining, a corner edge for transition, and a wiper edge for surface finishing. This segmentation allows each segment to perform its specific function optimally, enabling simultaneous achievement of high productivity and good surface finish.
Solution Approach 2:
Different portions of the cutting edge are given different geometric properties. The major cutting edge has a smaller angle for high-feed machining, while the wiper edge has a larger angle (155° or more) for surface finishing. This local differentiation of quality allows the tool to perform multiple functions with a single cutting insert.
2Manufacturing precision
If a wiper edge is added to improve surface roughness, then manufacturing precision is improved, but cutting resistance increases
Solution Approach 1:
The angle between the major cutting edge and the wiper edge is optimized to 155° or more, and a positive land with a positive land angle is introduced. These parameter changes reduce cutting resistance while maintaining the surface finishing function of the wiper edge, resolving the contradiction between surface quality and cutting force.
Data Source
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AI summary
A cutting insert capable of simultaneously achieving high-feed machining and finishing is provided. The cutting insert has an upper surface (21), a lower surface (91) and a side surface (61) that connects the two surfaces, and a cutting edge is formed at an intersecting edge between the upper surface (21) and the side surface (61). The cutting edge is at least comprised of a major cutting edge (33), a corner edge (34) connected to the major cutting edge (33), and a curved wiper edge (35) located on the opposite side of the major cutting edge (33) across the corner edge (34). The angle θ made by the major cutting edge (33) and the chord of the wiper edge (35) is 155≤θ<180°, and a positive land is formed in the wiper edge (35).