Cermet Cutting Insert Through-Hole Structure for Crack-Resistant Clamping
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Solution Overview
Problem
Existing cutting inserts made of cermet materials are prone to abnormal damage due to high local forces when fixed to holders, leading to cracking and reduced durability during cutting processes.
Innovation Solution
The insert design includes a binder-phase-riched layer in the inner wall of the through hole, with a higher binder phase content in the center part, which reduces deformation and local stress, preventing abnormal damage and improving clamping stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a cermet insert is fixed to a holder with high clamping force, then clamping stability is improved, but abnormal damage and cracking occur due to high local forces
Solution Approach 1:
The patent applies local quality by creating a binder-phase-riched layer specifically at the inner wall of the through hole where clamping force is applied. This localized modification allows the clamping area to have different mechanical properties (higher binder phase content for stress distribution) than the bulk material, enabling stable clamping without propagating cracks to the entire insert structure.
Solution Approach 2:
The binder-phase-riched layer acts as a pre-established cushioning zone that absorbs and distributes clamping stresses before they can cause damage. The higher binder phase content in this layer provides a compliant interface that reduces peak stresses during clamping, preventing abnormal damage before it occurs.
2Strength
If the binder phase content is increased in the through hole inner wall, then deformation and local stress are reduced, but manufacturing complexity increases
Solution Approach 1:
Instead of modifying the entire insert structure, the patent applies local quality by creating a binder-phase-riched layer only at the through hole inner wall. This localized approach achieves the desired stress resistance improvement without requiring complex global structural changes, maintaining manufacturing simplicity while enhancing local mechanical properties.
Data Source
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AI summary
An insert according to the present disclosure includes a base which is a cermet including hard particles and a binder phase. The base includes a first surface, a second surface, a cutting edge located on at least a part of a ridge line of the first surface and the second surface, a third surface located opposite to the first surface, and a through hole from the first surface to the third surface. An inner wall constituting the through hole includes a binder-phase-riched layer having a higher content of the binder phase than an inside of the base, at least in a center part. A thickness T1 of the binder-phase-riched layer in the center part is larger than a thickness T2 of the binder-phase-riched layer in an end part of the inner wall. A cutting tool according to the present disclosure includes a holder which has a length from a first end to a second end and includes a pocket located at a side of the first end, the insert located in the pocket, and a clamp inserted in the through hole of the insert.