3D-Printed Auxiliary Stone for Dressing-Free Diamond Segments

Solution Overview

Problem

Existing diamond tools require a dressing process to expose diamond grains, which is time-consuming and costly, and can cause thermal deformation of the shank and limit the tool's size due to high heat, complicating the manufacturing process.

Innovation Solution

A segment for a diamond tool is manufactured by sintering or hot pressing a mixture of diamond grains and a first powder, with an auxiliary stone part formed through 3D printing using a laser to laminate diamond grains and a second powder, eliminating the need for a dressing process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a dressing process is performed to expose diamond grains through the segment surface, then initial cutting force is improved, but manufacturing time and cost increase significantly

Engineering Contradiction:

Improveinitial cutting forceVSAvoidmanufacturing time

Core Design Contradiction:

StrengthVSLoss of time

Solution Approach 1:

The patent applies preliminary action by forming protrusions on the segment surface during the sintering or hot-pressing process itself, before the segment is installed on the tool shank. These protrusions are created by controlling the distribution and exposure of diamond grains during manufacturing, eliminating the need for subsequent dressing operations to expose the cutting elements.

Inventive Principle:

Principle #10Preliminary action

2Strength

If a dressing process is performed to expose diamond grains, then initial cutting force is improved, but manufacturing cost increases

Engineering Contradiction:

Improveinitial cutting forceVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent applies preliminary action by forming protrusions on the segment surface during the sintering or hot-pressing process itself, before the segment is installed on the tool shank. These protrusions are created by controlling the distribution and exposure of diamond grains during manufacturing, eliminating the need for subsequent dressing operations to expose the cutting elements.

Inventive Principle:

Principle #10Preliminary action

3Shape

If high heat is applied to melt and fuse diamond grains on segment surface, then diamond grain exposure is achieved, but thermal deformation of shank occurs

Engineering Contradiction:

Improvediamond grain exposureVSAvoidthermal deformation

Core Design Contradiction:

ShapeVSTemperature

Solution Approach 1:

The patent applies preliminary action by forming protrusions on the segment surface during the sintering or hot-pressing process itself, before the segment is installed on the tool shank. These protrusions are created by controlling the distribution and exposure of diamond grains during manufacturing, eliminating the need for subsequent dressing operations to expose the cutting elements.

Inventive Principle:

Principle #10Preliminary action

4Shape

If conventional fusion methods are used to form auxiliary stone part, then diamond grains are exposed, but the process becomes complicated and diamond grains are easily removed

Engineering Contradiction:

Improvediamond grain exposureVSAvoidprocess complexity

Core Design Contradiction:

ShapeVSDevice complexity

Solution Approach 1:

The patent applies preliminary action by forming protrusions on the segment surface during the sintering or hot-pressing process itself, before the segment is installed on the tool shank. These protrusions are created by controlling the distribution and exposure of diamond grains during manufacturing, eliminating the need for subsequent dressing operations to expose the cutting elements.

Inventive Principle:

Principle #10Preliminary action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution simplifies the manufacturing process, reduces thermal deformation, and ensures excellent initial cutting force without a dressing process, providing time and cost benefits while maintaining diamond grain integrity.

Implementation Method 1

an auxiliary stone part printed on the segment by 3D printing by which the diamond grains and a second powder are melted and laminated with a laser

Methodology Applied

Scientific EffectLaser: Laser

Implementation Method 2

a segment manufactured by sintering or hot-pressing a mixture formed by mixing diamond grains and a first powder

Methodology Applied

Scientific EffectSintering: Sintering

Data Source

PatentUS20250387832A1Segment for diamond tool and method of manufacturing the same

Publication Date: 2025.12.25 SHINHAN DIAMOND IND CO LTD

AI summary

A segment for a diamond tool according to the present invention includes a segment manufactured by sintering or hot-pressing a mixture formed by mixing diamond grains and a first powder, and an auxiliary stone part printed on the segment by 3D printing by which the diamond grains and second powder are melted and laminated with a laser.