Cutting Insert Wear Sensor Using Chip-Interconnected Leads
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Solution Overview
Problem
Existing cutting insert wear detection technologies face instability and unreliability due to fluctuating engagement between the work piece and the sensor lead, leading to unclear indications of wear and potential damage to the work piece.
Innovation Solution
A cutting insert with a sensor featuring two leads with free ends positioned to be interconnected by the metal work piece or chip, reducing the risk of interruption by cracks and providing a precise measurement of wear progression through changes in electric resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a lead is positioned on a clearance face in close proximity to a cutting edge to detect wear, then wear detection capability is improved, but the signal stability deteriorates due to fluctuating engagement between the work piece and the lead
Solution Approach 1:
The sensor is divided into multiple leads (at least two) with free ends positioned to be interconnected by the work piece or chip. This segmentation allows the system to detect wear through changes in electric resistance when the leads become interconnected, providing more stable and reliable wear detection signals compared to a single lead configuration.
2Measurement precision
If manual inspection of the cutting insert condition is performed, then measurement accuracy can be maintained, but productivity decreases due to time-consuming inspection processes
Solution Approach 1:
The cutting insert performs self-monitoring through the sensor system that automatically detects wear by measuring changes in electric resistance when leads become interconnected during operation. This eliminates the need for manual inspection while maintaining accurate wear detection, thereby improving productivity and operational efficiency.
Solution Approach 2:
The sensor provides continuous feedback about the cutting insert condition by measuring electric resistance changes. This feedback mechanism enables real-time monitoring of wear progression, allowing operators to make informed decisions about when to replace or reposition the cutting insert without manual inspection.
3Device complexity
If a single contact region sensor is used, then device complexity is reduced, but measurement precision deteriorates due to unstable engagement with the work piece
Solution Approach 1:
The sensor uses at least two leads with free ends that are positioned to be interconnected by the work piece or chip. This segmented approach creates multiple potential connection points, improving measurement reliability without significantly increasing device complexity. The leads can be arranged in simple patterns on the cutting insert surface.
Solution Approach 2:
The multiple leads are combined into a single sensor system that works together to detect wear. The leads are electrically connected to contact regions on the cutting insert and function collectively to measure changes in electric resistance, providing improved measurement precision while maintaining relatively simple device structure.
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
Enables precise and reliable detection of wear, preventing damage by clearly indicating when the cutting insert needs to be exchanged or repositioned, thus improving operational efficiency and preventing work piece damage.
Implementation Method 1
the resistance of the electric circuit as measured by means of said external measuring circuitry will change
Data Source
AI summary
A cutting insert for cutting, milling or drilling of metal includes a sensor for detecting a predetermined wear of the cutting insert caused by operation thereof on a metal work piece, wherein the sensor includes at least two contact regions through which the sensor is connectable to external measuring circuitry. The sensor has at least two leads, which are connected to a respective of the at least two contact regions, wherein each lead presents a respective free end positioned such that, upon the predetermined wear caused by the operation of the cutting insert on a metal work piece, the free ends will be connected to each other by the metal work piece or by a chip resulting from the operation of the cutting insert on the metal work piece.