Cutting Tool Machining Chain for Precision Shaping Hard Materials
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Solution Overview
Problem
The manufacturing of cutting tools made from high-hardness materials is challenging due to high costs, long machining times, and inaccuracies, particularly in precision cutting where tools like monocrystalline diamond, CVD-PCD, and cubic boron nitride are used, as existing methods like grinding and laser machining result in tool wear and unsatisfactory surface quality.
Innovation Solution
A multistep machining method involving data-driven process optimization, where a workpiece is subjected to a machining process chain with rough and fine machining steps, using laser processing and other methods to achieve precise geometries and surface qualities, with measurement and control systems to ensure accurate transfer between machining devices and minimize tool wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional grinding is used for macroforming, then the workpiece can be shaped, but the machining tool suffers from heavy abrasive wear and material removal is low
Solution Approach 1:
The patent replaces the conventional mechanical grinding system with a laser-based machining system. The laser beam acts as a non-contact tool that removes material through thermal ablation rather than mechanical abrasion, eliminating tool wear while maintaining shaping capability. This is achieved by focusing laser energy onto the workpiece surface to vaporize and eject material.
Solution Approach 2:
The patent changes the fundamental machining parameter from mechanical contact force to laser energy density. By controlling laser power, pulse duration, and scanning speed, the system achieves material removal without mechanical tool wear. The laser parameters are optimized to balance material removal rate with surface quality and minimize thermal damage.
2Productivity
If laser machining is used for rough machining with high advance speed, then material removal is large, but machining accuracy and surface smoothness are unsatisfactory
Solution Approach 1:
The patent divides the machining process into distinct stages: rough machining followed by finishing machining. During rough machining, higher laser power and faster advance speeds are used to remove large amounts of material. In the finishing stage, lower power and slower speeds are applied to achieve precise dimensions and smooth surfaces. This segmentation allows optimization of parameters for each specific machining objective.
Solution Approach 2:
The patent dynamically adjusts laser machining parameters during the process. The advance speed, power, and pulse duration are varied based on the machining stage and local material conditions. This dynamic parameter control enables the system to transition from high-productivity rough machining to high-precision finishing without requiring separate equipment.
3Manufacturing precision
If multiple independent machining devices are used for multistep machining, then rough and fine machining can be performed, but the process complexity and investment costs increase
Solution Approach 1:
The patent combines multiple machining functions into a single integrated laser machining device. The same laser system performs both rough machining and finishing operations by dynamically adjusting its parameters. This merging eliminates the need for multiple independent devices, reducing equipment investment, simplifying the production line, and minimizing workpiece handling between devices.
Solution Approach 2:
The laser machining device is designed with universal capability to perform multiple machining tasks. By controlling laser power, pulse duration, and advance speed, the single device can execute rough machining, finishing, and even heat treatment operations. This multi-functionality replaces several specialized devices with one versatile system.
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 method reduces tool consumption and machining time, achieving high accuracy and surface quality while extending tool life, allowing for efficient production of cutting tools with precise geometries and tolerances.
Implementation Method 1
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
Implementation Method 2
laser machining can be seen as a heat generating process which is attributed to adsorption of laser beam in the workpiece
Data Source
Figure 1
Figure 2~3
AI summary
A method for multistep machining a cutting tool comprises the steps of defining a data set (12) of the cutting tool comprising target geometries of the cutting tool, parameters of materials of the cutting tool and/or parameters of process operations for machining a workpiece (14) into the cutting tool, positioning the workpiece (14) in a machining device, determining a data set (18) of the workpiece (14) to be machined by a measuring method comprising actual geometries of shape, positional and orientation data of the positioned workpiece (14), defining at least one machining program (26, 28) for the machining device based on the defined data set (12) of the cutting tool in relation to the determined data set (18) of the workpiece (14), subjecting (20) the workpiece (14) to the at least one machining program (26, 28), whereby obtaining intermediate geometries of the workpiece (14), determining a second data set (22) of the workpiece (14) by measuring means comprising the intermediate geometries of the workpiece (14) and transferring the machined workpiece (14) to a second machining device. Furthermore, the method comprises repeating the steps of positioning, determining data set (18) of the workpiece (14), defining machining program (26, 28), subjecting the workpiece (14) to the machining program (26, 28), determining a second data set (22) and transferring to the second machining device until the workpiece (14) takes on the shape of the target geometries.