Diamond Sintered Cutting Edge for Flank Wear Resistance
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Solution Overview
Problem
Diamond sintered bodies in cutting tools often experience wear on the flank faces, leading to shortened tool life due to high dislocation density and inadequate wear resistance.
Innovation Solution
A cutting tool design featuring a diamond sintered body with a dislocation density of 8×10^15/m^2 or less on the flank face and 10×10^15/m^2 or less on the rake face, combined with a binder containing elements like cobalt, titanium, and tungsten, and a surface roughness of 120 nm or less, to enhance wear resistance and tool life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If diamond sintered body is used for cutting tool, then cutting performance is improved, but wear resistance on flank face deteriorates due to high dislocation density
Solution Approach 1:
The patent applies parameter changes by controlling the dislocation density to 8×10^15/m² or less and optimizing the binder phase composition (containing 3-15 mass% Ti, 3-15 mass% W, and 70-85 mass% Co) to resolve the contradiction between cutting performance and wear resistance. This specific parameter optimization enables the diamond sintered body to maintain both high cutting efficiency and improved flank face wear resistance.
2Duration of action of stationary object
If dislocation density is reduced to improve wear resistance, then tool life is extended, but manufacturing complexity increases
Solution Approach 1:
The patent achieves reduced dislocation density (8×10^15/m² or less) through optimized sintering parameters and binder composition, extending tool life while managing manufacturing complexity through controlled process parameters including specific temperature ranges and pressure conditions during sintering.
Solution Approach 2:
The patent uses a composite binder phase containing multiple elements (Ti, W, Co) in specific proportions to achieve the desired dislocation density and wear resistance. This composite approach allows optimization of material properties through compositional control rather than complex manufacturing processes.
3Manufacturing precision
If diamond grain size is reduced to improve cutting precision, then surface finish is improved, but strength of diamond grains deteriorates
Solution Approach 1:
The patent optimizes diamond grain size within the range of 0.1 μm to 50 μm and controls the binder phase composition to maintain adequate grain strength while achieving improved cutting precision and surface finish. The specific binder composition compensates for the reduced individual grain strength through enhanced inter-grain bonding.
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 reduced dislocation density and optimized binder composition improve wear resistance and thermal conductivity, extending the tool life by suppressing wear and thermal wear, while the surface roughness reduction further enhances tool longevity.
Implementation Method 1
A dislocation density in a portion of the flank face is 8×10^15/m^2 or less
Implementation Method 2
the binder phase contains at least one element selected from the group consisting of titanium, zirconium, hafnium, vanadium, niobium, tantalum, chromium, and molybdenum, of which content ratio is at least 0.5 mass % and less than 50 mass %, and contains cobalt, of which content ratio is at least 50 mass % and less than 99.5 mass %
Data Source
AI summary
A cutting tool includes a rake face, a flank face, and a cutting edge ridge line connecting the rake face and the flank face. A portion of the rake face and a portion of the flank face adjacent to the cutting edge ridge line are made of a diamond sintered body including diamond grains. A dislocation density in the portion of the flank face is 8×1015/m2 or less. The diamond grains have an average grain size of 0.1 μm to 50 μm. A content ratio of the diamond grains in the diamond sintered body is 80% by volume to 99% by volume.