Cutting Insert Pressure Welding for Faster Automated Joining
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Solution Overview
Problem
Existing methods for joining a cutting edge to a base in indexable cutting tools require skilled labor and are time-consuming, making automation difficult.
Innovation Solution
An insert manufacturing apparatus that uses electric current to directly join a cutting edge to a base via pressure welding, eliminating the need for brazing and allowing for automated assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If brazing is used to join the cutting edge to the base, then the joining strength is improved, but the manufacturing time increases and automation becomes difficult
Solution Approach 1:
The patent replaces the thermal-brazing process with a mechanical pressure welding process. The joining device applies direct mechanical pressure between the cutting edge and base, eliminating the need for heat-based brazing operations, skilled brazing workers, and associated long cycle times while achieving sufficient joining strength for cutting tool applications.
Solution Approach 2:
The patent changes the joining parameters from thermal parameters (temperature, heating rate) used in brazing to mechanical parameters (pressure, contact force) used in pressure welding. This parameter transformation enables automation through programmable pressure control while reducing the time required for the joining operation compared to thermal processing cycles.
2Strength
If brazing is used to join the cutting edge to the base, then the joining strength is improved, but the device complexity increases due to skilled labor requirements
Solution Approach 1:
The patent replaces the complex brazing process requiring skilled workers with a simplified mechanical pressure welding system. The joining device uses straightforward mechanical pressure application between electrodes, eliminating the need for skilled brazing operations, flux application, and thermal process control, thereby reducing overall process complexity despite adding some mechanical joining components.
3Loss of time
If direct joining without brazing is used, then the manufacturing time is reduced and automation is facilitated, but the joining strength may be compromised
Solution Approach 1:
The patent employs mechanical pressure welding as a direct joining method that eliminates brazing entirely. By applying sufficient mechanical pressure between the cutting edge and base through the joining device, it achieves adequate joining strength for cutting tool applications while significantly reducing manufacturing time and enabling full automation without requiring intermediate brazing materials or thermal processes.
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 direct joining method enhances joining strength, reduces manufacturing time, and facilitates automation, while minimizing burrs and maintaining dimensional accuracy.
Implementation Method 1
a current generator that generates an electric current flowing between the first electrode and the second electrode via the base and the cutting edge
Implementation Method 2
the cutting edge and the base to be directly joined. Here, the direct joining is joining performed by welding such as pressure welding between the cutting edge and the base
Data Source
AI summary
An apparatus for manufacturing an insert with a cutting edge joined to a base includes: a first electrode to contact the base; a second electrode to contact the cutting edge; a current generator for generating an electric current flowing between both the electrodes; and a moving device that moves the base contacting the first electrode and/or the cutting edge contacting the second electrode in a moving direction. A method of manufacturing the insert includes: providing the base; placing the cutting edge on a depression in the base; pressurizing the cutting edge on the base; and passing an electric current through the cutting edge and the base under pressurization. The insert for a cutting tool includes the cutting edge and the base directly joining each other. The base has adjacent first and second surfaces at predetermined angles, each surface having protrusion protruding from a contact surface where the cutting edge contacts, the protrusion softening and joining directly to the cutting edge when the cutting edge is joined in the depression.