Built-Up Edge Formation Material for Abrasion-Resistant Drilling

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Solution Overview

Problem

The existing methods for cutting fiber reinforced composite materials and metals, such as carbon fiber reinforced plastics (CFRP) and titanium alloys, result in short drill lifespans, poor hole quality due to abrasion, and issues like splintering, delamination, and burrs, leading to increased tooling costs and potential defects in aircraft structures.

Innovation Solution

A material for built-up edge formation comprising a resin block with high and medium molecular weight compounds and carbon, used in a built-up edge formation method to reduce cutting tool abrasion, comprising a resin block with a high molecular weight compound (A) having a weight average molecular weight of 5×10^4 to 1×10^6, a medium molecular weight compound (B) with a weight average molecular weight of 1×10^3 to 5×10^4, and carbon (C), which forms a built-up edge at the cutting tool edge, thereby prolonging tool lifespan and improving cutting work productivity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a drill is used for cutting fiber reinforced composite materials, then cutting work can be performed, but the drill lifespan becomes exceedingly short due to abrasion

Engineering Contradiction:

Improvecutting work capabilityVSAvoiddrill lifespan

Core Design Contradiction:

ProductivityVSDuration of action of moving object

Solution Approach 1:

The patent applies preliminary action by forming a built-up edge on the drill bit before actual cutting of the workpiece. This built-up edge is created by first cutting a sacrificial material (resin block with high/medium molecular weight compounds and carbon) that deposits material onto the drill cutting edge, preparing it for subsequent cutting operations and reducing abrasion during actual work

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent uses an intermediary material (resin block containing high molecular weight compound, medium molecular weight compound, and carbon) that acts as a mediator between the drill and the workpiece. This sacrificial material is cut first to create the built-up edge, serving as an intermediate step that protects the drill during subsequent cutting operations

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If a drill is used for cutting fiber reinforced composite materials, then holes can be created, but hole quality deteriorates due to drill abrasion causing small inside diameter, splintering, and delamination

Engineering Contradiction:

Improvehole creation capabilityVSAvoidhole quality

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The drill bit is prepared in advance by forming a built-up edge through cutting the sacrificial resin block material. This preliminary preparation ensures the cutting edge has optimal geometry and material deposition before actual hole cutting, preventing quality issues like splintering and delamination during production

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent changes the physical and chemical parameters of the cutting edge by depositing material from the resin block (containing specific molecular weight compounds and carbon) onto the drill bit. This material deposition alters the cutting edge properties, improving its ability to cut without causing quality defects

Inventive Principle:

Principle #35Parameter changes

3Productivity

If conventional drilling methods are used, then cutting work can be performed, but tooling costs increase due to frequent drill replacement

Engineering Contradiction:

Improvecutting work capabilityVSAvoidtooling cost

Core Design Contradiction:

ProductivityVSLoss of substance

Solution Approach 1:

The system becomes self-service by automatically forming the built-up edge on the drill bit through the cutting process itself. The sacrificial resin block material deposits onto the drill cutting edge during a preliminary cutting operation, creating a protective layer without requiring external coating processes or frequent tool replacement

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The resin block sacrificial material is discarded during the built-up edge formation process, but its material components (high molecular weight compound, medium molecular weight compound, carbon) are recovered and deposited onto the drill bit, creating a functional coating that extends tool life and reduces replacement costs

Inventive Principle:

Principle #34Discarding and recovering

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 significantly reduces cutting tool abrasion, prolongs tool lifespan, and enhances the quality of processed holes by minimizing splintering and delamination, leading to reduced tooling costs and improved productivity in cutting difficult-to-cut materials like CFRP and titanium alloys.

Implementation Method 1

forming a built up edge at the cutting edge of a cutting tool by cutting the material for built up edge formation with the cutting tool

Methodology Applied

Scientific EffectMaterial deposition: Deposition (physical)

Data Source

PatentUS11819930B2Material for built-up edge formation and built-up edge formation method

Publication Date: 2023.11.21 MITSUBISHI GAS CHEM CO INC

AI summary

The present invention provides a material for built up edge formation having a resin block containing a high molecular weight compound having a weight average molecular weight of 5×104 or higher and 1×106 or lower, a medium molecular weight compound having a weight average molecular weight of 1×103 or higher and lower than 5×104, and a carbon.