Conical Mirror Finishing Tool for High-Hardness Workpieces
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Solution Overview
Problem
Current mirror finishing tools using single-crystal diamond tips are ineffective for high-hardness materials like stainless steel and titanium, as they impose restrictions on cutting tool width, leading to low productivity due to the difficulty in machining and enlarging polycrystalline diamond and cubic boron nitride tools.
Innovation Solution
A mirror finishing method employing a conically shaped cutting tool made of polycrystalline diamond or cubic boron nitride, attached to a shank tilted during machining, allowing for a wider cutting width and improved productivity by dispersing machining forces and preventing tool detachment through electrical discharge machining with a wire electrode.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If single crystal diamond tip is used for mirror finishing, then mirror finishing capability is achieved, but it cannot be used for high hardness materials such as stainless steel or titanium
Solution Approach 1:
The patent changes the material parameter of the cutting tip from single crystal diamond to polycrystalline sintered diamond or cubic boron nitride, which have higher hardness and can effectively machine high-hardness materials like stainless steel and titanium while maintaining mirror finishing capability
Solution Approach 2:
The patent uses composite material structures where polycrystalline sintered diamond or cubic boron nitride tips are attached to the shank, combining the hardness of these materials with the structural integrity of the tool holder to achieve both high hardness machining and mirror finishing
2Strength
If polycrystalline sintered diamond or cubic boron nitride is used as cutting tool material, then high hardness machining is enabled, but the width of the cutting tool cannot be increased resulting in low productivity
Solution Approach 1:
The patent employs a spherical cutting tip geometry made of polycrystalline sintered diamond or cubic boron nitride, which allows the tool to maintain contact with the workpiece surface while enabling a wider effective cutting width compared to traditional geometric shapes, thereby improving productivity without compromising hardness capability
Solution Approach 2:
The patent transitions from conventional cutting tool geometries to a spherical tip configuration, utilizing three-dimensional spherical geometry to maximize the effective cutting width and surface contact area, enabling higher productivity while maintaining the ability to machine high-hardness materials
3Productivity
If the cutting tool width is increased to improve productivity, then machining efficiency increases, but it becomes difficult to machine and enlarge polycrystalline diamond and cubic boron nitride tools
Solution Approach 1:
The spherical geometry of the cutting tip simplifies the manufacturing process compared to other complex geometries, as spherical shapes can be more easily formed and enlarged through sintering and machining processes, while still providing increased cutting width for improved productivity
Solution Approach 2:
The patent employs preliminary sintering and pre-forming processes to create the spherical cutting tip structure before final attachment to the shank, making the overall manufacturing process more feasible and enabling the production of larger diameter tools without excessive difficulty
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 conical shape of the cutting tool allows for increased cutting width, preventing tool detachment and achieving a mirror finish without polishing lines, thereby enhancing productivity in finishing high-hardness workpieces like stainless steel and titanium.
Implementation Method 1
a conical surface of the cutting tool... by wire electrical discharge machining
Data Source
AI summary
A mirror finishing method for forming a mirror surface on a workpiece with a mirror finishing tool including a conically shaped cutting tool made of polycrystalline diamond or cubic boron nitride that is attached to a distal end of a shank, performs mirror polishing by abutting a conical surface of the cutting tool against a machined surface of the workpiece with the shank tilted with respect to the machined surface of the workpiece.