Chipper Tool Insert Resharpening and Replacement Method
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing cutting tools have a limited service life due to the inability to effectively resharpen cutting inserts beyond the support of stud-based structures, leading to premature tool replacement.
Innovation Solution
A method for repairing cutting tools by resharpening cutting inserts to protrude radially beyond the tool body, allowing multiple resharpenings without damaging the tool body, and using a material bond for secure attachment, enabling efficient replacement of worn inserts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If cutting inserts are repeatedly resharpened on stud-based tools, then the cutting edges can be restored, but the stud is gradually worn away and eventually removed, making further resharpening impossible
Solution Approach 1:
The cutting tool system is segmented into replaceable cutting inserts and a durable tool body. The cutting insert contains the cutting edge that can be resharpened multiple times, while the tool body provides a permanent mounting structure. This segmentation allows the cutting functionality to be restored repeatedly without affecting the tool body structure.
Solution Approach 2:
The cutting insert is designed as a disposable or replaceable component with a limited service life. After the cutting edge is worn beyond resharpening capability, the entire insert is replaced rather than attempting to restore it. This allows the expensive tool body to be reused indefinitely while the cheaper inserts are periodically replaced.
2Duration of action of moving object
If cutting inserts are resharpened multiple times, then the service life is extended, but the cutting insert material is gradually consumed and the insert becomes too short to function properly
Solution Approach 1:
The cutting insert is pre-configured with sufficient material height to accommodate multiple resharpening cycles. The initial design anticipates the cumulative material removal from repeated sharpening operations, ensuring the insert remains functional throughout its intended service life or until replacement is economically optimal.
Solution Approach 2:
The cutting insert is designed to be discarded after a predetermined number of resharpening cycles or when it reaches minimum functional dimensions. The tool body and mounting structure are recovered and reused, while the worn insert is replaced. This approach maximizes the utilization of the durable tool body component.
3Ease of repair
If the cutting insert is removed and replaced after resharpening, then a fresh cutting edge can be installed, but the mounting structure must remain intact to support the new insert
Solution Approach 1:
The system is divided into the cutting insert and the tool body with a dedicated mounting interface. The mounting structure (receiving pocket with support surface and clamping mechanism) is an integral part of the tool body that remains permanently intact. This segmentation enables easy replacement of the cutting insert while preserving the mounting structure for future inserts.
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The invention relates to a method for repairing a cutting tool. The cutting tool (1) comprises a tool body (2) and at least one cutting insert (10) with a cutting edge (11), separate from the tool body (2). The tool body (2) has an axis of rotation (3), rotates in a direction (4) about the axis of rotation (3) during operation of the cutting tool (1), and is provided with at least one receiving pocket (13) for the cutting insert (10). The tool body (2) is designed, at least partially, as a rotating body (20) with respect to the axis of rotation (3). The at least one receiving pocket (13) is machined into the surface of the rotating body (20) and has a contact surface (16) located within the circumferential contour of the rotating body (20), against which the cutting insert (10) rests.Before its very first use, the cutting insert (10) projects from the receiving pocket (13) beyond the outer contour of the rotating body (20) in the radial direction (50) with respect to the axis of rotation (3) by an initial height (ha). The cutting edge (11) of the cutting insert (10) is resharpened at least once and then projects from the receiving pocket (13) beyond the outer contour of the rotating body (20) in the radial direction (50) with respect to the axis of rotation (3) by a resharpening height (hn). The cutting insert (10) is removed from the contact surface (16) of the receiving pocket (13) when the resharpening height (hn) falls below a limit height (hg). Then a new cutting insert (110) with a new cutting edge (111) is inserted into the receiving pocket (13) and placed onto the contact surface (16).