Diamond Insert Chamfer Tool for Longer-Life Hard Material Machining
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Solution Overview
Problem
Chamfer tools with diamond-coated cutting edges for machining sintered cemented carbide and ceramics have short service lives, are cost-intensive, and require complex and expensive precision grinding, limiting their efficiency and affordability.
Innovation Solution
A chamfer tool with a tool holder made of cemented carbide and cutting inserts made of CVD thick-film diamond, featuring slot-shaped receptacles for secure attachment and precise cutting edges, allowing for high torque transmission and efficient machining of high-hardness materials with extended tool life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If solid cemented carbide chamfer tools with diamond-coated cutting edges are used, then cutting performance is improved, but service life becomes very short and manufacturing cost becomes very high
Solution Approach 1:
The cutting tool is divided into a tool holder and replaceable cutting inserts. The cutting inserts can be independently replaced when worn, while the tool holder is reused. This segmentation allows the cutting function to be separated from the tool body, enabling cost-effective replacement of only the cutting elements rather than the entire tool.
Solution Approach 2:
The cutting inserts are designed to be discarded after a certain service life and recovered (reused) by mounting new inserts on the same tool holder. This approach recovers the value of the tool holder structure while discarding only the consumable cutting inserts, reducing overall tooling costs and improving service life effectiveness.
2Productivity
If solid cemented carbide chamfer tools with diamond-coated cutting edges are used, then cutting performance is improved, but manufacturing cost becomes very high due to complex precision grinding
Solution Approach 1:
The cutting tool is divided into a tool holder and replaceable cutting inserts. The cutting inserts can be independently replaced when worn, while the tool holder is reused. This segmentation allows the cutting function to be separated from the tool body, enabling cost-effective replacement of only the cutting elements rather than the entire tool.
Solution Approach 2:
The cutting inserts are designed as disposable or limited-life components that can be replaced rather than regenerated. By making the cutting inserts replaceable and relatively inexpensive compared to solid diamond-coated tools, the overall manufacturing cost is reduced while maintaining cutting performance during the insert service life.
3Ease of manufacture
If cutting edges are made large or receptacle is made large to accommodate grinding tools, then cutting edge accessibility for grinding is improved, but the number of cutting edges or cutting inserts that can be attached to smaller tool holders is reduced
Solution Approach 1:
The cutting tool is divided into a tool holder and replaceable cutting inserts. The cutting inserts can be independently replaced when worn, while the tool holder is reused. This segmentation allows the cutting function to be separated from the tool body, enabling cost-effective replacement of only the cutting elements rather than the entire tool.
Solution Approach 2:
The cutting inserts are designed with a compact geometry that allows multiple inserts to be arranged in a circular pattern on the tool holder periphery. This dimensional arrangement maximizes the number of cutting edges that can be attached to the tool holder without requiring large receptacle dimensions, thereby increasing productivity through multiple simultaneously usable cutting edges.
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 chamfer tool achieves long service life, efficient machining of high-hardness materials with reduced stress and lower manufacturing costs, thanks to the stable connection and precise cutting edges, overcoming the limitations of traditional tools.
Implementation Method 1
cutting inserts made of CVD thick-film diamond... efficient machining of high-hardness materials
Data Source
AI summary
A chamfer tool which comprises a tool holder. The tool holder extends along a central axis and comprises a plurality of slot-shaped cutting insert receptacles, each having two opposing lateral abutment surfaces and a base abutment surface arranged between the two lateral abutment surfaces and extending transversely thereto. The chamfer tool further comprises a plurality of cutting inserts, which are fixed in the plurality of cutting insert receptacles in a firmly bonded manner, wherein each of the cutting inserts comprises two opposing lateral surfaces, which abut against or are connected in a firmly bonded manner to the two lateral abutment surfaces of the respective cutting insert receptacle, and a lower surface arranged between the two lateral surfaces and extending transversely thereto, wherein the lower surface abuts against or is connected in a firmly bonded manner to the base abutment surface of the respective cutting insert receptacle. The cutting inserts project out of the first cutting insert receptacles both in an axial direction, which is parallel to the central axis of the tool holder, and transversely to the axial direction. Each of the cutting inserts comprises a main cutting edge which is oriented at a first acute angle to the central axis of the tool holder.