Cutting Segment With Alternating Metal Matrix Layers
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Solution Overview
Problem
The use of powdered metal matrices in cutting tools for brittle materials like stone, brick, and concrete results in diamond particle segregation, reducing cutting efficiency and tool lifespan, and complicates the manufacturing process with high costs.
Innovation Solution
A cutting segment using plate-shaped metal matrices with alternating layers of diamond particles and metal matrices of different ductility, where diamond particles are uniformly distributed between soft and hard metal layers, simplifying the manufacturing process and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If powdered metal matrices are used in cutting segments, then the manufacturing process can be simplified, but diamond particle segregation occurs reducing cutting efficiency and tool lifespan
Solution Approach 1:
The cutting segment is divided into multiple layers with alternating diamond particle layers and metal matrix layers. This segmentation prevents diamond particle segregation by confining particles within specific layers, maintaining uniform distribution while simplifying the manufacturing process compared to traditional powdered metal matrices.
Solution Approach 2:
Diamond particles are embedded within metal matrix layers in a nested structure where the metal matrix surrounds and holds the diamond particles. This nesting approach ensures uniform distribution of diamond particles throughout the segment, preventing segregation while maintaining manufacturing simplicity.
2Ease of manufacture
If diamond particles are mixed with metal powders, then the segment can be manufactured, but non-uniform distribution occurs due to segregation
Solution Approach 1:
Instead of mixing diamond particles with metal powders, the invention segments the structure into distinct layers: diamond particle layers and metal matrix layers. This eliminates the segregation problem that occurs during mixing while maintaining ease of manufacture through a layering process.
Solution Approach 2:
The invention transitions from a three-dimensional mixed structure to a layered two-dimensional arrangement. By organizing diamond particles and metal matrix into alternating layers, the structure achieves uniform distribution without the segregation issues inherent in mixed powder formulations.
3Reliability
If patterning technology is used to distribute diamond particles uniformly, then cutting efficiency improves, but the manufacturing process becomes complex and costly
Solution Approach 1:
The invention achieves uniform diamond particle distribution through simple layering rather than complex patterning. By creating alternating layers of diamond particles and metal matrix, uniform distribution is obtained without requiring sophisticated patterning equipment or processes.
Solution Approach 2:
The invention changes the structural parameter from a mixed powder formulation to a layered configuration. This parameter change achieves uniform diamond particle distribution and improved cutting efficiency while avoiding the manufacturing complexity associated with patterning technologies.
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 solution ensures uniform diamond distribution, enhancing cutting efficiency and tool lifespan while simplifying the manufacturing process and reducing costs by eliminating the need for complex powder metallurgy steps.
Implementation Method 1
two kinds of plate-shaped metal matrix layers having different ductility... the metal matrix layer having relatively high ductility among the metal matrix layers
Implementation Method 2
A cutting segment for a cutting tool used for cutting or drilling brittle workpieces... comprising diamond particles as the abrasive material
Data Source
AI summary
A cutting segment for a cutting tool used for cutting or drilling brittle workpieces, such as stone, brick, concrete and asphalt, a method for manufacturing the segment, and a cutting tool comprising the segment are disclosed. The segment comprises layers of diamond particles and two kinds of plate-shaped metal matrix layers comprising soft and hard metal matrix layers having different ductility. The plate-shaped metal matrix layers are arranged perpendicular to a cutting surface while being parallel to a cutting direction, and are alternately stacked perpendicular to the cutting direction. The layers of diamond particles are suitably arranged in the plate-shaped soft and hard metal matrix layers. The segment and the cutting tool comprising the same have excellent cutting ability, and the manufacturing process thereof can be simplified, thereby remarkably enhancing productivity.