Cutting Insert Reworking Using 3D Boundary Surfaces

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Solution Overview

Problem

Existing cutting tools face issues with inaccurate positioning and shape of cutting inserts due to imprecise soldering, leading to poor quality and the need for time-consuming manual reworking, with a risk of errors and potential collisions during machining.

Innovation Solution

A method and device for automatic reworking of cutting inserts, utilizing three-dimensional surface analysis to determine cutting edge boundary surfaces without manual input, ensuring precise material removal within specified tolerances while avoiding collisions, using CAD data or surface scanners to generate cutting tool surfaces and control machining devices.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If cutting inserts are soldered directly onto the cutting tool body, then the connection is very strong, but the positioning accuracy and shape precision of the cutting inserts deteriorate

Engineering Contradiction:

Improveconnection strengthVSAvoidpositioning accuracy and shape precision

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The patent applies preliminary action by determining the three-dimensional surface of the cutting tool and identifying cutting edge boundary surfaces before the actual machining operation. This pre-analysis allows the system to plan the material removal paths in advance, compensating for the positioning inaccuracies introduced by soldering. The movement paths are calculated beforehand to ensure precise material removal despite the initial positioning errors.

Inventive Principle:

Principle #10Preliminary action

2Manufacturing precision

If manual reworking is performed to correct positioning inaccuracies, then the cutting tool quality can be improved, but the time consumption and error risk increase

Engineering Contradiction:

Improvecutting tool qualityVSAvoidreworking time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent replaces manual mechanical reworking with an automated machining system. A machining device with a material removal device (such as a laser or electrical discharge machine) and a movement device controlled by a computer automatically performs the material removal based on pre-calculated paths. This substitution eliminates manual errors and significantly reduces the time required for reworking while maintaining high precision.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system changes the operational parameters by using non-contact or highly controlled material removal methods. Instead of manual operations with variable human performance, the system uses programmable movement paths and controlled energy input (laser or electrical discharge) to achieve consistent, precise material removal. The parameters such as movement speed, energy intensity, and path coordinates are precisely controlled to optimize both quality and efficiency.

Inventive Principle:

Principle #35Parameter changes

3Measurement precision

If complex manual input is required for probe measurement and path determination, then measurement accuracy can be achieved, but the operation complexity and error potential increase

Engineering Contradiction:

Improveposition detection accuracyVSAvoidoperation complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The system applies self-service by enabling the machining device to automatically determine its own movement paths based on the three-dimensional surface data of the cutting tool. The computer controlling the movement device calculates the paths autonomously without requiring complex manual programming or detailed operator intervention. The system uses the measured surface data to self-determine the material removal paths, reducing operational complexity while maintaining measurement precision.

Inventive Principle:

Principle #25Self-service

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

Facilitates accurate and efficient reworking of cutting inserts, reducing labor and error-prone manual input, ensuring precise cutting edge formation within specified tolerances, and preventing collisions during machining.

Implementation Method 1

a laser for generating a laser beam

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Implementation Method 2

an electrical discharge machine (EDM)

Methodology Applied

Scientific EffectElectrical discharge machining: Electrical Discharge Machining

Data Source

PatentUS20260086529A1Method for machining a cutting tool, and machining device for carrying out the method

Publication Date: 2026.03.26 ROLLOMATIC SA

AI summary

In a method for machining a cutting tool and a machining device for carrying out the method, the cutting tool includes a cutting tool body and at least one cutting insert with at least one cutting edge attached to the cutting tool body. A three-dimensional surface of the cutting tool is predetermined. Cutting edge boundary surfaces are determined from this surface, which form a surface of the cutting insert and are located adjacent to a cutting edge of the cutting insert. The machining device is controlled on the basis of these cutting edge boundary surfaces and removes material from the cutting insert in a targeted manner, whereby a collision between the cutting tool and a material removal device of the machining device is prevented.