The paper presented a method of designing grooves of turning insert with 3D complex groove; and deduced equation calculating the width of the grooves using condition equation of the chip breaking, the parameters included in the equation was taken place by equivalent ones. And the grooves width is computed by MATLAB, and then the curve of the groove is fitted. The width can be used to create model of the turning inserts with 3D complex groove by Pro/Engineer, and the model can be imported in ANSYS soft to simulate turning process and analysis groove performance. All this work provides a base for the groove design and optimization

The measuring temperature and force experiments of cutting heat-resistance steel (3Cr-1Mo-1/4V alloy and 1Cr18Ni9 alloy) by plane milling insert and milling insert with complex groove that invented by ourselves has been done, meanwhile, the falling process of sticking-welding chip when milling insert cut-in and cut-out has been observed by high-speed photograph. Mechanical-thermal coupled field has been analyzed using ANSYS, and equivalent complex stress of the coupled field is larger than the stress of single field distinctly, it shows that they have a relation of direct proportion. The results of test and analysis show that the main reasons of adhesion failure are heat that produced in cutting process and the change of temperature grads during cut-in or cut-out and alternate tension stress and stress impact during cut-in or cut-out., which provides technical support and experimental data for the groove's optimization and reconstruction of milling insert with 3D complex groove.

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In the design and optimization of cutting tool’s groove, it is necessary to comprehensively consider the multidisciplinary coupling effects of stress field, temperature field and working environment, and balance the coupling effects on the cutting performance. The multidisciplinary optimization method is employed to study the 3D complex groove reconstruction of cutting tools in this paper. The two-level reconstruction approach is proposed. The groove reconstruction of waved-edge insert is presented as a numerical example, and an optimal design of the groove is obtained. The optimization results show that the reconstructed tool has a satisfied performance on the stress field and temperature field.