Diamond Tool Cutting Segment with Superimposed Particle Layers
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Solution Overview
Problem
Diamond tools used for cutting brittle materials like stone and concrete suffer from rounding wear (R wear), leading to reduced useful life and cutting efficiency, as the outer diamond particle rows fall off easily, despite previous attempts to address this through increased diamond concentration or harder binders, which complicate manufacturing and do not sufficiently reduce wear.
Innovation Solution
A cutting segment design with at least two diamond particle layers superimposed on the side, featuring blank sections between the layers to distribute load and prevent wear, where the depth and arrangement of depressions control the gap between these sections to optimize cutting rate and life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If diamond particle rows are arranged only on the cutting surface without superimposition, then the structure is simple and manufacturing is easy, but the outer diamond rows suffer from rounding wear and fall off easily, reducing useful life
Solution Approach 1:
The patent transitions from a single-layer diamond particle arrangement to a multi-layer stacked structure with superimposition in the thickness direction. This dimensional change allows outer diamond rows to be protected by inner layers, preventing rounding wear and particle loss, thereby extending the useful life of the cutting segment while managing the increased structural complexity through systematic layering.
2Reliability
If diamond concentration is increased at the side to reduce R wear, then wear resistance improves, but the manufacturing process becomes more complex
Solution Approach 1:
The patent divides the cutting segment into multiple diamond particle layers stacked in the thickness direction, with each layer containing diamond particles arranged in rows. This segmentation allows the outer layers to protect inner layers from rounding wear, providing wear resistance through structural design rather than increasing diamond concentration, thereby avoiding manufacturing complexity associated with selective concentration adjustment.
3Duration of action of moving object
If multiple diamond particle layers are superimposed on the side, then R wear is reduced and useful life is extended, but the manufacturing process becomes more complex
Solution Approach 1:
The patent uses superimposition of diamond particle layers in the thickness direction to protect outer diamond rows from rounding wear. This approach extends useful life through a systematic multi-layer structure that can be manufactured using standardized stacking processes, balancing the extension of service life with manageable manufacturing complexity.
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 significantly reduces R wear, enhances cutting efficiency, and extends the useful life of the cutting segment by protecting the outer diamond rows and adjusting the blank section gaps to effectively utilize every diamond particle, resulting in improved performance compared to conventional designs.
Implementation Method 1
a cutting segment of a diamond tool comprising: a number of diamond particles arranged in a plurality of plate-shaped layers stacked perpendicular to a cutting direction
Data Source
AI summary
The invention relates to a cutting segment of a diamond tool for cutting or drilling a brittle workpiece such as stone, bricks, concrete and asphalt, and a diamond tool having the same. The invention allows superior cutting rate and lengthy useful life without suffering from R wear during cutting. In the cutting segment, a number of diamond particles are arranged in a plurality of plate-shaped layers stacked perpendicular to a cutting direction. Each of the diamond particle layers has a plurality of particle rows on a cutting surface. Further, at least two of the diamond particle layers are superimposed on at least one side of the cutting segment seen from the front of the cutting segment in cutting direction. The invention ensures uniform cutting by significantly reducing R wear that arises during cutting and thus enables superior cutting rate and longer useful life.