Sensor-Integrated Cutting Insert for Reliable Wear Detection
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Summary
Problems
Existing cutting inserts lack reliable and durable sensor arrangements that are susceptible to damage and interference during machining, leading to inefficient monitoring and potential workpiece damage due to wear or unfavorable operating conditions.
Innovation solutions
A cutting insert design with a sensor arrangement featuring a lead placed in a narrow recess, protected by an insulating layer, which reduces the risk of damage and interference, allowing for reliable wear detection and improved operational efficiency.
TRIZ Analysis
Specific contradictions:
General conflict description:
Principle concept:
If the sensor lead is placed on the surface of the cutting insert, then the sensor arrangement is easily accessible and simple to manufacture, but the lead is susceptible to damage and interference during machining operations
Why choose this principle:
The sensor lead is nested within a recess in the cutting insert body, with the insulating layer surrounding the lead. This nesting protects the lead from external damage while maintaining electrical functionality, resolving the contradiction between accessibility and durability.
Principle concept:
If the sensor lead is placed on the surface of the cutting insert, then the sensor arrangement is easily accessible and simple to manufacture, but the lead is susceptible to damage and interference during machining operations
Why choose this principle:
An insulating layer is introduced as an intermediary between the sensor lead and the external environment (substrate and machining conditions). This mediator protects the lead from damage and interference while allowing the sensor to function, addressing both reliability and manufacturability concerns.
Application Domain
Data Source
AI summary:
A cutting insert design with a sensor arrangement featuring a lead placed in a narrow recess, protected by an insulating layer, which reduces the risk of damage and interference, allowing for reliable wear detection and improved operational efficiency.
Abstract
A cutting insert (100, 200) for cutting, milling or drilling of metal comprises a body having an elongate recess (111, 1111) extending along at least a portion of the body, a first layer (120, 1120) covering interior side walls (112, 113) of the recess, and a sensor arrangement. The body comprises a substrate (110). The sensor arrangement comprises a lead (130, 230, 240) extending along the recess. The lead comprises electrically conductive material which is arranged in the recess such that the first layer is located between the electrically conductive material and the substrate. For at least a depth (D1, D2, D5) below which at least a portion of the electrically conductive material is arranged in the recess, a width (W2, W3, W4) of the recess measured at that depth between portions of the first layer covering opposite interior side walls (112, 113) of the recess is less than or equal to 80 micrometers.