Composite Drill Head Structure for Simpler Ultra-Hard Cutting Tools
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Solution Overview
Problem
Existing methods for producing cutting tools are limited in versatility and ease of production, particularly when dealing with nonferrous metals, plastics, composite materials, and hardened steels, as they often require complex sintering processes and multiple layers that can be cumbersome to manufacture and design.
Innovation Solution
A method where a hard metal support layer protrudes over the basic body, allowing for the formation of active cutting edges and chip guiding portions through processes like grinding, laser processing, or die sinking, enabling a more flexible design and production of cutting tools with ultra-hard layers such as PCD or CBN.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple layers and complex sintering processes are used to produce cutting tools, then the cutting tool can achieve required hardness and durability, but the manufacturing complexity and difficulty increase significantly
Solution Approach 1:
The cutting tool is divided into distinct functional layers: a hard metal support layer providing structural integrity and a PCD/CBN cutting layer providing ultra-hard cutting edges. This segmentation allows each layer to be optimized independently for its specific function, simplifying the overall manufacturing process while maintaining high reliability
Solution Approach 2:
The invention uses composite material construction combining hard metal (tungsten carbide-based) with ultra-hard materials (PCD or CBN). This composite structure enables the cutting tool to achieve both the durability required for reliable operation and the cutting performance needed for hard materials, while the modular composite approach simplifies manufacturing compared to monolithic structures
2Ease of manufacture
If traditional multi-layer cutting tool designs are used, then cutting performance can be achieved, but design versatility and ease of production are limited
Solution Approach 1:
The hard metal support layer serves multiple functions: providing structural support, enabling various cutting edge geometries through selective removal, and allowing integration of chip control structures. This multi-functionality increases design versatility while maintaining ease of manufacture through a standardized base structure
Solution Approach 2:
The hard metal support layer is prepared in advance with a protruding configuration before the PCD/CBN layer is applied. This preliminary action enables subsequent flexible shaping and chip control structure integration without requiring complex rework, thus improving both ease of manufacture and design versatility
3Manufacturing precision
If the cutting edge is formed only in the ultra-hard layer, then cutting performance is achieved, but chip control and tool geometry flexibility are reduced
Solution Approach 1:
The invention extends the functional structure into the third dimension by having the hard metal support layer protrude beyond the PCD/CBN layer. This dimensional extension provides access for chip control structures and allows geometric shaping that would be impossible if the cutting edge were confined only to the ultra-hard layer surface
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
This approach allows for a broader range of design possibilities and simplifies the production of cutting tools, enabling the creation of cutting edges and chip guiding surfaces that can be easily formed and integrated into various machining tools like drill bits and milling tools, enhancing their performance and applicability.
Implementation Method 1
The cutting element is soldered with its ultra-hard layer in a recess of the basic body
Implementation Method 2
whereby the hard metal support layer is ground in order to form the cutting edge with adjoining chipping surface
Implementation Method 3
by a laser process
Implementation Method 4
by a die sinking process
Data Source
AI summary
The invention relates to a drilling tool (50), in particular a dowel hole drill, for the machining of workpieces, in particular workpieces made of wood, plastics, composite materials, comprising a drill shaft (56) with a front surface (60), and to a drill head (58) with at least one cutting edge (66), which is firmly connected, such as soldered, to the drill shaft (56). In order to make available a drilling tool of the type mentioned at the start, which has a broad range of application and is simple to produce, it is provided that the drill head (58) is formed from a composite material with exclusively two layers (38), namely a hard metal layer (36) and an ultra-hard layer (38) which is connected to the hard metal layer (36) and preferably formed from polycrystalline diamond or polycrystalline boron nitride, that the ultra-hard layer (38) is connected directly to the front surface (60) of the drill shaft (56) and that the at least one cutting edge (66) is formed by the ultra-hard layer (38), and a drill bit (62) such as a centering tip is formed by the hard metal layer (36).