Resin-Coated Cutting Insert for Surface-Safe Wear Indication

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Solution Overview

Problem

Existing cutting tools with coating layers on inserts can lead to surface corruption of workpieces due to contact between the workpiece and the coating layer during the cutting process, and there is a need to determine if an insert has been used without damaging the processing surface.

Innovation Solution

The insert includes a base member with a resin layer only on the rake surface region, allowing easy identification of usage and preventing contact with the flank surface, which enhances durability by avoiding excessive temperature rise and maintaining a well-finished processing surface.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a coating layer is applied to the entire base member including the flank surface, then the base member is protected and durability is improved, but the processing surface of the workpiece becomes corrupted due to contact between the workpiece and the coating layer on the flank surface

Engineering Contradiction:

Improvedurability of base memberVSAvoidsurface corruption of workpiece

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The resin layer is applied selectively only to the rake surface region of the base member, not to the flank surface region. This local differentiation allows the rake surface to have protective and heat-resistant properties while keeping the flank surface free of coating material that would otherwise corrupt the workpiece processing surface.

Inventive Principle:

Principle #3Local quality

2Reliability

If a coating layer is applied to the rake surface, then heat resistance and durability are improved, but it becomes difficult to determine whether the insert has been used

Engineering Contradiction:

Improvedurability of base memberVSAvoidusage status of insert

Core Design Contradiction:

ReliabilityVSDifficulty of detecting and measuring

Solution Approach 1:

The resin layer is provided in a color different from the base member. When the insert is used, the resin layer peels off, creating a visible color change that clearly indicates the usage status of the insert. This color differentiation makes it easy to determine whether the insert has been used without requiring complex detection methods.

Inventive Principle:

Principle #32Color changes

3Difficulty of detecting and measuring

If the resin layer is located on the second surface (flank surface), then identification of usage is possible, but the processing surface of the workpiece becomes corrupted due to contact with the resin layer

Engineering Contradiction:

Improveusage status of insertVSAvoidsurface corruption of workpiece

Core Design Contradiction:

Difficulty of detecting and measuringVSObject-affected harmful factors

Solution Approach 1:

Instead of placing the resin layer on the flank surface (second surface) to enable usage identification, the invention inverts the approach by placing the resin layer on the rake surface (first surface). This inversion allows usage identification through color change while preventing the resin layer from contacting and corrupting the workpiece processing surface, since the flank surface remains free of resin material.

Inventive Principle:

Principle #13The other way round (Inversion)

Data Source

PatentUS11123812B2Insert and cutting tool

Publication Date: 2021.09.21 KYOCERA CORP

AI summary

An insert may include a base member and a resin layer located on the base member. The base member may include a first surface, a second surface, and a cutting edge. The first surface includes a rake surface region. The second surface may be adjacent to the first surface and includes a flank surface region. The cutting edge may be located in at least a part of a ridge line at which the first surface intersects with the second surface. The resin layer may not be located on the second surface but may be located on the first surface.