Composite Cutting Edge Material for Heat-Resistant Alloy Machining
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Solution Overview
Problem
Cutting tools used for difficult-to-cut materials like nickel-based heat-resistant alloys face challenges in wear resistance, fracture resistance, and heat resistance, particularly with sintered diamond and cubic boron nitride particles, which have limitations in hardness and thermal stability.
Innovation Solution
A cutting tool with a composite sintered material containing diamond and cubic boron nitride particles, where the volume ratio of the hard phase is between 0.6 to 0.99, and the cubic boron nitride particles are between 0.1 to 0.4, with a specific particle size distribution and a cobalt-containing binder phase, integrated with a cemented carbide core and a helix angle between 35° to 75°, enhancing wear and fracture resistance and heat resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If sintered diamond particles are used for the cutting edge, then hardness is improved, but heat resistance deteriorates
Solution Approach 1:
The cutting edge is constructed as a composite material containing both diamond particles and cubic boron nitride particles. Diamond provides superior hardness while cubic boron nitride contributes high heat resistance, creating a synergistic effect where the composite material achieves both high hardness and high heat resistance that neither material could achieve alone.
2Temperature
If sintered cubic boron nitride particles are used for the cutting edge, then heat resistance is improved, but hardness deteriorates
Solution Approach 1:
The cutting edge is constructed as a composite material containing both diamond particles and cubic boron nitride particles. Diamond provides superior hardness while cubic boron nitride contributes high heat resistance, creating a synergistic effect where the composite material achieves both high hardness and high heat resistance that neither material could achieve alone.
3Loss of substance
If the cutting edge is made of sintered diamond or cubic boron nitride, then wear resistance is improved, but fracture resistance deteriorates
Solution Approach 1:
The cutting edge is constructed as a composite material containing both diamond particles and cubic boron nitride particles. Diamond provides superior hardness while cubic boron nitride contributes high heat resistance, creating a synergistic effect where the composite material achieves both high hardness and high heat resistance that neither material could achieve alone.
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 cutting tool exhibits improved wear resistance, fracture resistance, and heat resistance, as demonstrated by extended tool life in cutting tests with nickel-based alloys, with the composite sintered material forming a skeleton structure that prevents crack propagation and maintains thermal stability.
Implementation Method 1
a composite sintered material containing a plurality of diamond particles and a plurality of cubic boron nitride particles
Implementation Method 2
the composite sintered material forming a skeleton structure that prevents crack propagation
Implementation Method 3
maintains thermal stability
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
A cutting tool according to an aspect of the present disclosure includes a shank, a joint, and a cutting portion attached through the joint to the shank. The cutting portion includes a core and a surface portion. The surface portion is disposed around a central axis of the cutting portion to cover an outer circumferential surface of the core. The surface portion includes a cutting edge. The cutting edge is disposed on an outer circumferential surface of the surface portion and formed in a helical shape about the central axis. The surface portion is a composite sintered material including a hard phase formed of a plurality of diamond particles and a plurality of cubic boron nitride particles, and a binder phase forming the remainder.