Cermet Cutting Insert Through-Hole Structure for Abnormal Damage Resistance
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Solution Overview
Problem
Existing cermet cutting inserts, particularly those with titanium as a main component, face issues with abnormal damage during high-load cutting processes due to uneven stress distribution and lack of adequate wear resistance at critical contact points.
Innovation Solution
The insert features a cermet base with a binder-phase-riched layer in the through hole, where the binder phase content is higher than in the base, particularly in the center part. This configuration includes a thicker binder-phase-riched layer in the center compared to the ends, enhancing the insert's resistance to abnormal damage by distributing force more evenly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a uniform binder phase distribution is used in the through hole, then the manufacturing process is simpler, but the insert suffers from abnormal damage during high-load cutting due to uneven stress distribution
Solution Approach 1:
The patent applies local quality by creating a binder-phase-ricked layer with non-uniform binder phase distribution within the through hole. The center part has a higher binder phase content and greater thickness (T1) compared to the end parts (T2), which allows the structure to locally adapt to stress distribution patterns during high-load cutting, thereby improving resistance to abnormal damage while maintaining overall structural integrity.
2Reliability
If the binder phase content is increased throughout the entire base, then wear resistance improves, but the hardness and strength of the cutting edge deteriorates
Solution Approach 1:
The patent resolves this contradiction by locally increasing the binder phase content only in the binder-phase-ricked layer at the through hole, while maintaining the original binder phase content in the bulk base material. This localized approach allows the ricked layer to provide enhanced wear resistance at the mounting interface without compromising the hardness and strength of the cutting edge in the main body of the insert.
Solution Approach 2:
The patent segments the insert structure into distinct regions with different binder phase characteristics: the binder-phase-ricked layer in the through hole with higher binder phase content for wear resistance, and the bulk base material with standard binder phase content for maintaining cutting edge hardness and strength. This segmentation allows each region to optimize its properties for its specific functional requirements.
Data Source
AI summary
An insert includes a base of a cermet including hard particles and a binder phase. The base includes first and second surfaces, a cutting edge on at least a part of a ridge line of the first and second surfaces, a third surface 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 of the binder-phase-ricked layer in the center part is larger than a thickness of the binder-phase-ricked layer in an end part of the inner wall. A cutting tool includes a holder which has a pocket located at an end, the insert located in the pocket, and a clamp inserted in the through hole of the insert.