Cutting Segment With Perpendicular Abrasive Layers
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Solution Overview
Problem
Cutting segments for brittle materials like stone, bricks, and concrete face challenges in achieving a balance between cutting rate and useful life due to uneven dispersion of diamond particles, leading to segregation and reduced retention, which affects the efficiency and longevity of the cutting tool.
Innovation Solution
The cutting segment is designed with abrasive particle layers arranged perpendicular to the cutting direction, featuring alternating thin and thick blank sections to optimize the retention and protrusion of diamond particles, ensuring even distribution and enhanced cutting performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If diamond particles are randomly dispersed in metal powder, then manufacturing is simple, but cutting rate and useful life are reduced due to uneven distribution and segregation
Solution Approach 1:
The cutting segment is divided into multiple layers with diamond particles arranged in specific patterns (rows and columns) rather than random dispersion. This segmentation into structured layers improves cutting rate by ensuring uniform diamond distribution while maintaining manufacturing feasibility through systematic assembly processes
Solution Approach 2:
Different regions of the cutting segment have different diamond particle arrangements and concentrations. The diamond particles are positioned at specific intervals and depths to create optimal cutting edges in different zones, improving overall cutting performance while allowing tailored manufacturing approaches for different segments
2Productivity
If metal powder with low abrasion resistance is used, then cutting rate is enhanced, but useful life is shortened
Solution Approach 1:
The cutting segment uses a composite structure combining metal powder matrix with strategically positioned diamond particles. This composite design allows the metal matrix to provide structural support and controlled abrasion while diamond particles maintain cutting sharpness, achieving both high cutting rate and extended useful life through material synergy
Solution Approach 2:
Diamond particles are pre-positioned in specific arrangements within the metal matrix before sintering. This preliminary arrangement ensures optimal cutting edges are formed during manufacturing, allowing the segment to maintain high cutting rate from the start while the structured distribution prevents premature wear and extends useful life
3Productivity
If diamond particles are uniformly arranged in rows and layers, then cutting rate and useful life are improved, but manufacturing complexity increases
Solution Approach 1:
The complex diamond arrangement is achieved by dividing the cutting segment into modular layers, each containing diamond particles in standardized row patterns. This segmentation allows complex overall structures to be built from simpler repeating units, improving cutting performance while managing manufacturing complexity through modularity
Solution Approach 2:
The invention optimizes specific parameters such as diamond particle size, spacing intervals, and layer thickness to achieve uniform distribution. By carefully controlling these parameters within specific ranges, the patent achieves improved cutting rate and useful life while keeping manufacturing processes within feasible complexity limits
4Ease of manufacture
If diamond particles are randomly dispersed, then manufacturing is easier, but particle retention is reduced leading to premature wear
Solution Approach 1:
The metal matrix is designed with localized properties that enhance diamond particle retention at specific positions. Binding agents or metal powder compositions are optimized in regions where diamond particles are positioned to ensure strong adhesion, preventing premature wear while allowing simple mixing processes for the overall composite
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 arrangement enhances the cutting rate and extends the useful life of the cutting segment by maintaining sufficient diamond particle retention and preventing premature wear, allowing for efficient cutting of large debris without compromising on cutting speed.
Implementation Method 1
To cut or drill a brittle work piece such as stone, bricks, concrete and asphalt requires abrasive particles having higher hardness than a work piece
Implementation Method 2
mixing the diamond particles with the metal powder serving as a bond
Data Source
AI summary
The invention provides a cutting segment for a cutting tool for cutting or drilling a brittle work piece such as stone, bricks, concrete and asphalt, and a cutting tool having the cutting segment. The cutting segment includes a cutting surface for cutting a work piece and a plurality of abrasive particle layers. The abrasive particle layers are disposed perpendicular to a cutting direction. Each of the abrasive layers has a plurality of abrasive particle rows in a width direction of the cutting segment. Each of the abrasive rows has a plurality of abrasive particles arranged in a line. Further, the abrasive layers have a plurality of blank sections therebetween. In the blanks sections, abrasive particles are absent or have a concentration of 70% or less with respect to those in the abrasive rows. In addition, the blank sections include relatively thick blank sections and relatively thin blank sections.