Cutting Insert Tool Set With Radial Side Punches
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Solution Overview
Problem
Existing methods for manufacturing cutting inserts with undercut features face challenges in releasing and extracting the compacted green bodies from die cavities due to the presence of these features, which inhibit the process.
Innovation Solution
A tool set configured with a central axis, radial punch and die channels, and adjustable punches and die rods allows for compaction and precise positioning of sinterable powder to form a green body, enabling the formation of complex shapes and facilitating the removal of the green body by transitioning through various configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If cutting inserts with undercut features are pressed using conventional punches and dies, then the desired complex geometry can be achieved, but the release and extraction of the compacted green body from the die cavity is inhibited
Solution Approach 1:
The tool set is divided into multiple independent components: upper punch, lower punch, side punches, and die rods that can move relative to each other. This segmentation allows the cavity to transition between closed and open states, enabling extraction of green bodies with undercut features that would otherwise be trapped in conventional fixed dies.
Solution Approach 2:
The die system transitions from a static conventional die to a dynamic system where side punches and die rods can radially move. The side punches move radially inward during compaction and can then move outward to open the cavity, allowing green bodies with complex geometries to be released and extracted without deformation.
2Manufacturing precision
If high pressures are applied through large opposing forces to compact sinterable powder, then adequate density and strength of green body is achieved, but the device complexity increases due to large force requirements
Solution Approach 1:
The compaction process transitions from uniaxial compression (single dimension) to multi-axial compaction by adding radial movement of side punches and die rods. This distributes the compaction forces across multiple directions, achieving adequate density and strength without requiring excessively large opposing forces in a single direction.
Solution Approach 2:
The upper punch, lower punch, side punches, and die rods work together in a coordinated manner to apply compaction forces from multiple directions simultaneously. This merging of multiple force application points creates effective compaction while distributing the mechanical load, reducing the complexity of individual force generation systems.
3Force
If side punches are positioned remote from the base through hole prior to compaction, then adequate compaction pressure can be applied, but the side punches must move through a larger distance during compaction
Solution Approach 1:
The die rods are pre-positioned adjacent to the base through hole in both the first configuration (prior to compaction) and second configuration (after compaction). This preliminary positioning of the die rods eliminates the need for side punches to traverse large distances, as the die rods are already in place to guide and support the compaction process from the outset.
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 approach ensures the successful compaction and removal of green bodies with complex geometries, such as nonlinear minor edges and intersecting surfaces, improving the manufacturing process by allowing for precise control and efficient extraction of the green body.
Implementation Method 1
the side punches move slidably on the die guiding surfaces
Data Source
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AI summary
A method for manufacturing a cutting insert green body from a sinterable powder, a tool set for manufacturing the cutting insert green body by that method and the green body manufactured by the tool set. The tool set has axially moving upper and lower punches and radially moving side punches. The side punches move slidably on die rods. The side punches and die rods move in channels in a base body on which a cover plate is mounted. The upper and lower punches move in through holes in the cover plate and base body, respectively. The die rods are stationary during compaction of the sinterable powder. The upper, lower and side punches form surfaces of the green body and the die rods form some of the edges of the green body. The green body can have undercuts and the edges formed by the die rods can be non-linear in shape.