Diamond Throw-Away Tip Chip Breaker for Spiral Chip Control
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Solution Overview
Problem
Existing throw-away tips with diamond blades face challenges in achieving excellent chip processability due to difficulties in forming a chip breaker that can curl chips spirally and maintain a sharp cutting edge, leading to aggravated surface roughness and limited durability.
Innovation Solution
A throw-away tip with a blade containing 80% diamond and a chip breaker design featuring a recess with a rake face that recedes continuously, similar to a body of revolution, allowing chips to flow out and distort effectively, enhancing chip processability and maintaining cutting edge strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a chip breaker is formed by electro-discharge machining or grinding, then the chip breaker can be shaped, but it cannot curl chips spirally and cannot obtain desired chip processability
Solution Approach 1:
The invention applies a curved surface profile to the rake face of the chip breaker, specifically defining it as a portion of a body of revolution with continuous curvature. This curved geometry enables chips to follow a spiral path along the rake face, effectively curling them and improving chip processability, while being manufacturable through conventional processes.
2Ease of manufacture
If a chip breaker is formed by electro-discharge machining, then the chip breaker can be created, but the blade's cutting edge cannot be formed sharply, aggravating finished surface roughness
Solution Approach 1:
The invention replaces electro-discharge machining with a mechanical forming process (such as pressing or molding) to create the chip breaker. This mechanical approach allows for precise control of the cutting edge geometry, producing a sharp edge that maintains excellent finished surface quality on workpieces.
3Reliability
If diamond is used for a blade to improve strength and wear resistance, then the throw-away tip gains durability, but diamond is not easily processed to form a chip breaker excellent in chip processability
Solution Approach 1:
The invention forms the chip breaker structure on the diamond blade through a preliminary forming process (such as pressing or molding) before the diamond blade is fully sintered or set. This preliminary action allows the complex curved geometry to be established when the material is more formable, after which the diamond structure provides the required durability.
Solution Approach 2:
The invention changes the physical state or formability parameters of the diamond-containing material during manufacturing. By controlling the sintering pressure, temperature, or using a green compact state, the material becomes sufficiently formable to create the complex curved chip breaker geometry, while the final sintered product achieves the required hardness and wear resistance.
Data Source
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AI summary
There is provided a throw-away tip which includes a blade containing diamond and is excellent in chip processability. The throw-away tip comprises a body and a blade provided to the body and having a cutting edge, the blade containing 80% by volume or more of diamond, the blade having a land surface extending along the cutting edge, and a chip breaker having a recess located opposite to the cutting edge with the land surface therebetween, the recess having a side surface having an inclined surface that recedes continuously as a distance thereof from the land surface increases in magnitude and that has a shape identical to that of a portion of a side surface of a shape of a body of revolution.