Natural Diamond Endmill Normal-Temperature Bonding
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Solution Overview
Problem
Conventional diamond endmill tools face challenges in machining precision due to interference during abrading and grinding processes, alignment errors, and high-temperature welding, which lead to increased costs and reduced reproducibility.
Innovation Solution
A method involving the sequential abrading and grinding of natural diamond gemstones with sub-bodies, followed by normal-temperature bonding of the machining tip with a super hard body, allowing for precise alignment adjustments on X, Y, and Z axes using existing equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the machining tip is welded with the body installed in equipment using high-temperature welding solution, then the machining tip is fixed to the body, but the dimension of the machining tip varies due to thermal effects
Solution Approach 1:
The patent changes the temperature parameter from high-temperature welding to normal-temperature bonding using bonding agent 15. This eliminates thermal expansion and dimensional variation while maintaining bonding strength through chemical adhesion rather than thermal fusion.
2Ease of manufacture
If the machining tip is not accurately aligned during installation, then the assembly process is simple, but the runout of the endmill tool is not accurately matched, lowering product reproducibility
Solution Approach 1:
The patent performs preliminary alignment adjustment by temporarily installing the machining tip 12 in the super hard body 11 using alignment adjustment equipment 300 before final bonding. This allows precise positioning on X, Y, and Z axes to be established prior to permanent fixation, ensuring both ease of adjustment and high alignment accuracy.
3Strength
If a body having the machining tip fixed thereto is present during abrading or grinding process, then the machining tip is protected, but the body interferes with the grinding wheel within machining range
Solution Approach 1:
The patent divides the manufacturing process into sequential stages: first abrading/grinding the natural diamond gemstone 1 while mounted on sub-bodies 20, then separating it and mounting on the final super hard body 11 only after the machining tip 12 is fully formed. This segmentation eliminates interference from the final body during critical abrading operations while maintaining tip security through progressive mounting.
4Manufacturing precision
If natural diamond gemstone is used instead of polycrystalline diamond, then machining precision is enhanced through single crystal structure, but the cost of material increases
Solution Approach 1:
The patent uses inexpensive sub-bodies 20 as temporary mounting fixtures during the abrading and grinding processes. These sub-bodies serve their purpose during manufacturing and are discarded or reused, rather than using expensive super hard bodies throughout the entire process. This reduces material cost while preserving the precision benefits of natural diamond.
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 enhances machining precision, reduces manufacturing costs, minimizes interference during processing, and ensures reliable machining by allowing for precise alignment adjustments, thereby preventing costly errors and failures.
Implementation Method 1
an abrading step of forming a lower base surface and an upper reference surface of the natural diamond gemstone by using an abrading equipment
Implementation Method 2
an grinding step of grinding an edge portion of the natural diamond gemstone by using a grinding equipment
Implementation Method 3
bonding the machining tip with the super hard body by using a normal-temperature bonding agent through a normal-temperature coagulation scheme
Data Source
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AI summary
Disclosed is a method of manufacturing an endmill tool, including detecting a crystal direction of a selected natural diamond gemstone (1) by inspecting the structure of the diamond gemstone (S100), forming a lower base surface (S20) and an upper reference surface (S230) of the diamond gemstone by using abrading equipment after welding the diamond gemstone with a first sub-body (20a, 20b, 20c), grinding (S300) an edge portion of the diamond gemstone by using grinding equipment after welding a machining tip, which is separated from the first sub-body (20a, 20b, 20c), with a second sub-body (30) to complete the machining tip having a cutting blade, and temporarily installing (S400) the machining tip, which is separated from the second sub-body, in a super hard body installed in setting equipment, adjusting an alignment state of the machining tip, and bonding the machining tip with the super hard body by using a normal-temperature bonding agent through a normal-temperature coagulation scheme to complete the endmill tool.