Cutting Insert Sharpening Without Removal or Repositioning
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Solution Overview
Problem
Existing methods for sharpening used removable machining inserts often require dismantling, fail to maintain dimensional and geometric parameters, and result in additional costs due to reconditioning and reassembly challenges, limiting the number of usable sharpenings and efficiency.
Innovation Solution
A method that sharpens only the cutting face of the insert at a non-zero angle, maintaining specific dimensional and geometric parameters, allowing multiple sharpenings without dismantling and preserving the insert's geometric compatibility with the tool holder, thereby extending the tool's lifespan and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If traditional sharpening methods are used to restore the cutting edge, then the insert can be reused, but the insert must be removed from the tool holder and repositioned, causing loss of time and positioning uncertainty
Solution Approach 1:
The insert sharpens itself while remaining mounted on the tool holder. The grinding device grinds the cutting face of the insert in place, eliminating the need for removal and manual repositioning. The insert remains self-contained on the holder throughout the sharpening process.
Solution Approach 2:
The cutting face is ground at a non-zero angle relative to the original cutting face orientation. This preliminary angular grinding creates a new cutting edge while maintaining proper geometric parameters, preparing the insert for continued use without requiring subsequent repositioning operations.
2Manufacturing precision
If the insert is disassembled and resharpened to restore the cutting edge, then the cutting edge sharpness is improved, but reassembly difficulties and repositioning tolerance issues arise
Solution Approach 1:
The insert remains on the tool holder during sharpening, eliminating disassembly and reassembly operations. The in-place grinding process restores cutting edge sharpness while the insert maintains its original positioned relationship with the holder, avoiding all repositioning tolerance issues.
3Manufacturing precision
If multiple inserts are sharpened individually by removal, then each insert can be resharpened, but uncertainties due to repositioning affect consistency
Solution Approach 1:
Multiple inserts mounted on the same tool holder are sharpened simultaneously in their fixed positions. Since each insert remains mounted during grinding, there is no repositioning uncertainty, and all inserts achieve consistent sharpness based on their original precise mounting locations.
4Ease of manufacture
If the cutting face is ground parallel to the original face, then the sharpening process is simple, but the dimensional and geometric parameters of the insert are not maintained
Solution Approach 1:
The cutting face is ground at a controlled non-zero angle relative to the original cutting face. This angular approach is performed as a preliminary step to create a fresh cutting edge while systematically maintaining the insert's dimensional and geometric parameters within acceptable tolerances.
Solution Approach 2:
The grinding angle is changed from the original cutting face angle to a non-zero relative angle. This parameter change in the grinding orientation allows material removal that creates a new cutting edge while controlling the resulting geometric parameters to remain within specification tolerances.
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 method enables two to ten times more sharpenings than traditional methods, maintains the insert's geometric compatibility, and eliminates repositioning uncertainties, resulting in significant cost and time savings by allowing the reused insert to function like a new one.
Implementation Method 1
the sharpening is carried out on the cutting face by removing material from said cutting face on said first damaged edge
Data Source
Figure 1~2
Figure 3~4
Figure 4A~5
AI summary
The present invention concerns a method for sharpening a worn removable machining tip (3) and the corresponding sharpened tip. The tip having a first cutting edge (7) damaged after a first use (u1), said tip having, in the state prior to the use of same, specific dimensional and geometrical parameters within a defined tolerance range and said first undamaged cutting edge (7) having a defined sharpness, the method involves sharpening the cutting face (9) by removing material from said cutting face on said first damaged edge (7), in order to make said tip (3) match said specific dimensional and geometrical parameters within said defined tolerance range, having a second cutting edge (7') of said defined sharpness.