Chamfering Tool CVD Diamond Inserts Segmentation
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Solution Overview
Problem
Chamfering tools for sintered hard metal and ceramics have short service life, are cost-intensive due to diamond-coated cutting edges that require precise grinding, and are limited in the number of cutting edges that can be attached to smaller tool holders due to large cutting edge designs.
Innovation Solution
A chamfering tool with a hard metal tool holder and CVD thick-film diamond cutting inserts, where the inserts are securely attached via soldering on three sides, allowing for high torque transmission and efficient machining of hard materials, enabling a longer service life and cost-effective production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If diamond-coated cutting edges are used on solid cemented carbide tools, then cutting performance on hard materials is improved, but tool life becomes very short and production cost increases
Solution Approach 1:
The tool is divided into a carbide tool holder and separate diamond cutting inserts. The diamond inserts are mounted on the tool holder rather than being solid diamond tools, allowing the cutting edges to be replaced when worn while retaining the expensive tool holder.
Solution Approach 2:
The diamond cutting inserts are designed to be replaceable when they wear out. The expensive carbide tool holder is retained and reused, while only the relatively inexpensive diamond inserts are discarded and replaced, reducing overall tooling costs and extending effective tool life.
2Manufacturing precision
If diamond-coated cutting edges require very high precision grinding, then cutting precision is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The diamond inserts are pre-ground and pre-coated with cutting edges of precise geometry before being mounted on the tool holder. This preliminary preparation allows the final assembly to be simple and does not require complex on-site grinding equipment.
3Ease of manufacture
If cutting edges are made relatively large to allow access to grinding tools, then grinding accessibility is improved, but the number of cutting edges that can be mounted on smaller tool holders decreases
Solution Approach 1:
The cutting tool is segmented into a tool holder and separate replaceable inserts, allowing small inserts to be mounted on compact tool holders while maintaining adequate size for each insert to be properly ground and coated during manufacturing.
Solution Approach 2:
Multiple cutting edges are arranged in a circular pattern around the tool holder, utilizing the circumferential dimension. This allows many cutting inserts to be mounted on the tool holder simultaneously, increasing the number of available cutting edges without increasing the size of individual inserts.
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 tool achieves a stable and precise chamfering process with extended tool life, efficiently machining hard materials with reduced stress and cost, while allowing for a higher number of cutting edges on smaller tool holders.
Implementation Method 1
A plurality of cutting inserts of the same shape and size made of CVD thick-film diamond
Implementation Method 2
the inserts are securely attached via soldering on three sides
Data Source
Figure 1
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AI summary
The invention relates to a chamfering tool (10) for producing a chamfer on a workpiece, wherein the chamfering tool (10) has a tool holder (12) made of carbide, which extends along a central axis (14) and has a first slot-like cutting insert receptacle (18a), which has two mutually opposite lateral contact faces (24, 28) and a bottom contact face (32) that is arranged between the two lateral contact faces (24, 28) and extends transversely thereto, said bottom contact face (32) forming a bottom of the first slot-like cutting insert receptacle (18a). The chamfering tool (10) also has a first cutting insert (20a) made of CVD thick-layer diamond, which is fastened in a materially bonded manner in the first cutting insert receptacle (18a), wherein the first cutting insert (20a) has two mutually opposite lateral faces (22, 26), which bear against the two lateral contact faces (24, 28) of the first cutting insert receptacle (18a) or are connected in a materially bonded manner thereto, and an underside (30) that is arranged between the two lateral faces (22, 26) and extends transversely thereto, said underside (30) bearing against the bottom contact face (32) of the first cutting insert receptacle (18a) or being connected in a materially bonded manner thereto, and wherein the first cutting insert (20a) protrudes from the first cutting insert receptacle (18a) both in the axial direction, i.e. parallel to the central axis (14) of the tool holder (12), and transversely to the axial direction, and has a main cutting edge (36), which is oriented at a first acute angle (γ) to the central axis (14) of the tool holder (12).