Cutting Insert Surface Topography via Inverse Punch Imprinting
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Solution Overview
Problem
The extreme hardness and abrasion resistance of materials like PCD or PCBN make it difficult and expensive to machine surface topography features for cutters and machine tool inserts, which are necessary for effective chip diversion and surface finish improvement.
Innovation Solution
A method involving a pre-formed body of hard material with a surface topography, an aggregated mass of superhard material, and a ceramic punch with inverse topography, subjected to high pressure and temperature in the presence of a sinter catalyst to form a polycrystalline superhard material with complementary surface features, allowing for efficient and cost-effective production of cutter structures with enhanced machining performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If PCD or PCBN materials are used for cutting inserts, then hardness and abrasion resistance are improved, but the ability to machine surface topography features deteriorates
Solution Approach 1:
The surface topography is pre-formed on the substrate before the superhard material is applied. This preliminary action allows the complex surface features to be created when the material is still relatively easy to machine, avoiding the need to machine the extremely hard PCD or PCBN material itself.
Solution Approach 2:
Instead of machining the surface topography into the hard superhard material after it is applied, the process inverts the sequence: the surface topography is first created on the substrate, then the superhard material is conformally deposited over it. This inversion solves the machinability problem while preserving the desired surface features.
2Reliability
If surface topography features are added to cutting inserts, then chip diversion and surface finish quality are improved, but manufacturing complexity and cost increase
Solution Approach 1:
The substrate preparation step combines multiple functions: it creates the surface topography features and provides the base layer for superhard material deposition. This merging of functions into a single preparatory step simplifies the overall manufacturing process while achieving the desired chip diversion capabilities.
Solution Approach 2:
The substrate's surface topography automatically serves as the mold for the superhard material layer, which conformally replicates the features. This self-service approach eliminates the need for separate molding or machining steps to create the surface features, reducing manufacturing complexity.
3Reliability
If surface topography features are added to cutting inserts, then chip breaker functionality is improved, but manufacturing cost increases
Solution Approach 1:
The chip breaker surface features are pre-formed on the substrate before superhard material application. This preliminary creation of features avoids the costly and complex process of machining or forming these features into the expensive superhard material after it is applied.
Solution Approach 2:
The superhard material layer conformally copies the surface topography features from the substrate. This copying approach is more cost-effective than attempting to machine or form the same features directly into the superhard material, as it utilizes the substrate as a reusable mold.
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 method enables the production of cutter structures with improved machining performance and surface topography features that can divert chips or act as chip breakers, reducing the need for complex and costly machining processes.
Implementation Method 1
subjecting the aggregated mass of grains of superhard material, the punch and the body of hard material to a pressure of greater than 3 GPa in the presence of the sinter catalyst material for the grains of superhard material at a temperature sufficiently high for the catalyst material to melt, sintering the grains to form the cutter structure
Implementation Method 2
at a temperature sufficiently high for the catalyst material to melt
Data Source
Figure 1~4e
AI summary
A method of making a cutter structure (1) comprises placing a pre-formed body (4) of hard material having a surface topography in a canister, placing an aggregated mass of grains of superhard material (2) over said surface topography, placing a punch (10) in contact with the superhard material (2), the punch (10) having a surface with a surface topography inverse to that of the hard material body to imprint a pattern in the superhard material (2) complementary to the surface topography of the punch (10). The surface of the punch (10) contacting the superhard material (2) being formed of a ceramic material that does not react chemically with the superhard material (12) and/or a sinter catalyst for the superhard material (2). A pressure of greater than 3 GPa is then together with a temperature sufficiently high for the catalyst to melt to form the cutter structure (1) with a layer of polycrystalline superhard material bonded to the hard material and having a surface topography corresponding to the surface topography of the hard material.