Built-Up Edge Formation Material for Abrasion-Resistant Drilling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The cutting work of fiber reinforced composite materials and metals using drills results in short tool lifespan, poor hole quality due to abrasion, splintering, and delamination, leading to increased costs and safety concerns, particularly in aerospace applications where high-quality cutting is critical.
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 medium molecular weight compound, and carbon, which forms a built-up edge on the cutting tool, reducing wear and prolonging tool lifespan.
Engineering Contradictions & Design Principles
Engineering 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 extremely short due to abrasion
Solution Approach 1:
A resin block is introduced as an intermediary material between the drill and the fiber reinforced composite material. The resin block absorbs the abrasion and wear that would otherwise occur on the drill, forming a built-up edge that protects the drill cutting edge. This mediator allows the drill to cut through the difficult-to-cut composite material while significantly extending drill lifespan.
Solution Approach 2:
The resin block is positioned in advance before the actual cutting of the composite material begins. By pre-forming a built-up edge on the drill through cutting the resin block, the drill is prepared with a protective layer that will reduce abrasion during subsequent cutting operations on the composite material.
2Productivity
If a drill is used for cutting fiber reinforced composite materials, then holes can be created, but hole quality deteriorates with increased number of processed holes
Solution Approach 1:
The resin block serves as a mediator that maintains consistent cutting conditions. By forming a built-up edge that protects the drill, it ensures uniform hole quality across multiple processed holes, preventing the deterioration that would normally occur as the drill wears from repeated use.
3Strength
If cutting resistance increases in high strength CFRP, then tensile strength is maintained, but drill abrasion increases rapidly
Solution Approach 1:
The resin block is positioned between the drill and the high strength CFRP to absorb the harmful abrasion effects. The built-up edge formed from the resin block protects the drill from direct contact with the abrasive carbon fibers, allowing the high strength CFRP to be cut without rapid drill wear.
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 method significantly reduces cutting tool abrasion, prolongs tool lifespan, and improves cutting work productivity by forming a built-up edge that enhances the cutting ability and dimensional accuracy, thereby reducing the frequency of tool changes and processing costs.
Implementation Method 1
A material for built up edge formation comprising a resin block containing: a high molecular weight compound (A) having a weight average molecular weight of 5 × 10 4 to 3 × 10 6, a medium molecular weight compound (B) having a weight average molecular weight of 1 × 10 3 to 5 × 10 4, and carbon (C) having a predetermined average particle size
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The present invention provides a material for built up edge formation having a resin block containing a high molecular weight compound (A) having a weight average molecular weight of 5 × 104 or higher and 1 × 106 or lower, a medium molecular weight compound (B) having a weight average molecular weight of 1 × 103 or higher and lower than 5 × 104, and a carbon (C).