Cutting Tool Machining Chain for Precision Hard-Material Forming
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Solution Overview
Problem
The accurate and efficient manufacturing of cutting tools made from high-hardness materials like monocrystalline diamond, CVD-PCD, and cubic boron nitride is challenging due to high costs, lengthy machining times, and unsatisfactory surface quality, particularly in precision machining where tight tolerances are required.
Innovation Solution
A multistep machining method involving data-driven process optimization, where a workpiece is subjected to a machining process chain with initial macroforming using high-speed laser processing and subsequent microforming through laser ablation or electrical discharge machining, with integrated measurement and control systems to achieve precise geometry and surface quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional grinding is used for macroforming, then the cutting tool geometry can be formed, but the machining time is long and tool wear is high
Solution Approach 1:
The machining process is divided into two distinct stages: macroforming (rough machining) and microforming (finishing). Each stage uses optimized parameters and methods suited to its specific requirements, allowing efficient material removal in the first stage and precise surface finishing in the second stage without compromise
Solution Approach 2:
Different machining parameters are applied for macroforming and microforming operations. The macroforming stage uses parameters optimized for high material removal rates, while the microforming stage uses parameters optimized for surface quality and precision, resolving the contradiction between productivity and manufacturing precision
2Productivity
If laser machining is used for macroforming with high advance speed, then material removal is large and machining time is reduced, but the machining accuracy and surface smoothness deteriorate
Solution Approach 1:
The laser machining process is segmented into macroforming (rough machining) and microforming (finishing) stages. The macroforming stage uses high advance speed for efficient material removal, while the microforming stage uses lower advance speed and optimized parameters to achieve required surface quality and precision
Solution Approach 2:
The process maintains continuous useful action by seamlessly transitioning from macroforming to microforming without removing the workpiece from the machining system. The microforming stage immediately follows macroforming to refine the surface, ensuring both high productivity and surface quality are achieved in one continuous process
3Adaptability or versatility
If multiple independent machining devices are used for multistep machining, then different machining methods can be applied, but the device complexity and investment cost increase
Solution Approach 1:
Multiple machining functions (macroforming and microforming) that would traditionally require separate independent devices are merged into a single integrated machining device. This allows different machining methods to be applied in sequence while reducing device complexity and investment cost
Solution Approach 2:
The machining device is designed with multi-functionality to perform both macroforming and microforming operations. The device can adapt different machining methods and parameters for different stages of the process, providing versatility without requiring multiple specialized devices
4Manufacturing precision
If conventional grinding is used for finishing operations, then surface quality can be improved, but the tool life is shortened due to heavy abrasive wear
Solution Approach 1:
The conventional mechanical grinding process is replaced with laser-based microforming for finishing operations. This substitution eliminates direct mechanical contact between the tool and workpiece, avoiding heavy abrasive wear and significantly extending tool life while maintaining or improving surface quality
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 reduces machining times and costs by optimizing the process chain, ensuring high accuracy and surface quality, and minimizing tool wear, thereby producing cutting tools with precise geometries and small tolerances efficiently.
Implementation Method 1
Especially laser machining for roughly machining the workpiece is performed using operation parameters for high advance speed to form rough desired contour resulting in large material removal. Depending on the laser used, laser machining can be seen as a heat generating process which is attributed to adsorption of laser beam in the workpiece.
Implementation Method 2
at least one process for performing finishing, referred as microforming... laser ablation with different operation parameters to obtain required surface qualities
Implementation Method 3
at least one process for performing finishing, referred as microforming... or electrical discharge machining
Data Source
AI summary
A method for multistep machining a cutting tool includes defining a data set of the cutting tool, positioning the workpiece in a machining device, determining a data set of the workpiece to be machined, defining at least one machining program based on the defined data set in relation to the determined data set of the workpiece, subjecting the workpiece to the at least one machining program, to obtain intermediate geometries of the workpiece, determining a second data set by measuring means including the intermediate geometries of the workpiece and transferring the machined workpiece to a second machining device. Furthermore, the steps of positioning, determining data set of the workpiece, defining machining program, subjecting the workpiece to the machining program, determining a second data set and transferring to the second machining device are repeated until the workpiece takes on the shape of the target geometries.