Diamond-Coated Cutting Edge Structure to Prevent Flank Peeling
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Solution Overview
Problem
The existing cutting tools with hard coatings on the flank face side are prone to peeling off due to principal cutting forces, resulting in insufficient durability of the cutting edge during the cutting process.
Innovation Solution
A cutting tool design featuring a diamond layer covering both the rake and flank faces, with a negative angle configuration between the top faces that supports the cutting force from below, increasing the contact area and adhesiveness, and a rounded tip radius to enhance durability and sharpness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a hard coating is applied to the flank face side of the cutting tool, then the initial durability is improved, but the diamond layer peels off during cutting due to principal cutting forces
Solution Approach 1:
Instead of applying the diamond layer directly on the flank face as in conventional tools, this invention inverts the sequence by first forming a negative land face on the base material, then applying the diamond layer on top of it. This inverted structure allows the base material to support the cutting forces before the diamond layer is applied, preventing peeling while maintaining adhesion.
Solution Approach 2:
The flank face is segmented into two distinct surfaces: the negative land face (first top face) and the upper flank face (second top face). This segmentation allows the negative land face to specifically bear the principal cutting forces while the upper flank face maintains the diamond layer coverage, resolving the contradiction between force support and layer adhesion.
2Manufacturing precision
If the diamond layer is removed from the rake face to improve cutting sharpness, then the cutting edge becomes sharper, but the durability is reduced
Solution Approach 1:
The diamond layer is selectively removed only from the rake face while maintaining full coverage on the flank face and negative land face. This local quality approach preserves cutting sharpness on the rake face where chip flow occurs, while maintaining durability on the flank face where cutting forces are applied.
Data Source
AI summary
A cutting tool includes: a rake face; a flank face continuous to the rake face; and a cutting edge formed by a ridgeline between the rake face and the flank face. The cutting tool includes: a base material having a first face on a side of the rake face and a second face on a side of the flank face; and a diamond layer covering the first face and the second face. The first face includes: a first top face continuous to the second face; and a second top face continuous to the first top face and disposed such that the first top face is sandwiched between the second top face and the second face. An angle formed between the first top face and the second top face is a negative angle in a cross section perpendicular to the cutting edge.