3D-Printed Diamond Tool Segment Without Dressing
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Solution Overview
Problem
Existing diamond tools require a dressing process to expose diamond grains, which is time-consuming and costly, and can cause thermal deformation of the shank and limit tool size due to high heat processes.
Innovation Solution
A segment for a diamond tool is manufactured by sintering or hot pressing a mixture of diamond grains and a first powder, with an auxiliary stone part formed through 3D printing using a laser to laminate diamond grains and a second powder, eliminating the need for a dressing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a dressing process is performed to expose diamond grains through the segment surface, then initial cutting force is improved, but manufacturing time and cost increase significantly
Solution Approach 1:
The patent applies preliminary action by forming protrusions on the segment surface during the sintering process itself, before the segment is installed on the tool. The protrusions are created by controlling the sintering conditions so that diamond grains naturally protrude from the segment surface, eliminating the need for subsequent dressing operations. This advance preparation resolves the contradiction by achieving good initial cutting force without the time-consuming dressing process.
2Reliability
If a dressing process is performed to expose diamond grains, then initial cutting force is improved, but manufacturing cost increases
Solution Approach 1:
The invention performs the grain exposure action during the primary sintering process rather than as a separate dressing operation. By controlling sintering parameters (temperature, pressure, atmosphere) to naturally form protrusions, the process integrates what would otherwise be a separate costly operation into the base manufacturing step, thereby reducing total manufacturing cost while maintaining reliable initial cutting force.
3Reliability
If high heat processes like laser ablation or electrolysis are used for dressing, then diamond grains are exposed, but thermal deformation of the shank occurs
Solution Approach 1:
The patent performs grain exposure during the sintering process at temperatures controlled to affect only the segment material, not the attached shank. By timing the grain protrusion formation to occur during segment sintering before or during controlled cooling, the method achieves diamond grain exposure without subjecting the shank to the extreme localized heat of laser ablation or electrolysis, thus preventing thermal deformation and maintaining shank dimensional stability.
4Reliability
If conventional fusion methods are used to form auxiliary stone parts, then diamond grains can be fused, but the shank undergoes thermal deformation
Solution Approach 1:
The invention performs diamond grain fusion during the initial sintering process under controlled atmosphere and temperature conditions that are sufficient to fuse diamond grains to the segment matrix but controlled in duration and distribution to avoid excessive heat accumulation that would deform the shank. The sintering process parameters are optimized to achieve grain fusion while limiting thermal exposure of the shank, resolving the contradiction between effective grain fusion and shank stability.
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 method simplifies the manufacturing process, reduces thermal deformation, and ensures excellent initial cutting force without a dressing process, providing automated formation and reduced processing time.
Implementation Method 1
an auxiliary stone part printed on the segment by 3D printing by which the diamond grains and a second powder are melted and laminated with a laser
Implementation Method 2
a segment manufactured by sintering or hot-pressing a mixture formed by mixing diamond grains and a first powder
Data Source
Figure 1
Figure 2a~2b
Figure 3~4
AI summary
A segment for a diamond tool according to the present invention includes a segment manufactured by sintering or hot-pressing a mixture formed by mixing diamond grains and a first powder, and an auxiliary stone part printed on the segment by 3D printing by which the diamond grains and second powder are melted and laminated with a laser.