Diamond Tool Cold-Worked Base Notch Attachment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing diamond tools face challenges such as labor-intensive and costly assembly processes due to thermal methods like brazing and welding, which can damage diamond segments and require multiple tool bodies for different applications, leading to increased production costs and complexity.
Innovation Solution
A diamond tool with a cold-workable base made from metals like copper, iron, or stainless steel, fixed to the tool body through mechanical crimping or pressing, eliminating the need for heat and using notches that can be beveled for enhanced attachment, allowing for flexible segment placement and tool reconditioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thermal processes such as brazing and welding are used to fasten diamond segments to the tool body, then the segments can be securely attached, but the temperature increase damages the diamond segments and requires additional notches and substrate modifications
Solution Approach 1:
The patent replaces the thermal process (brazing/welding) with a mechanical cold-working process. The base is inserted into a notch in the tool body and then cold-worked (pressed, crimped, or swaged) to expand the base laterally, creating friction and mechanical interlocking with the notch walls. This mechanical attachment method eliminates thermal damage to diamond segments while achieving secure attachment.
Solution Approach 2:
The patent changes the physical state and properties of the base material by using cold-working processes. The base is made from workable metal or alloy that can be deformed at room temperature. During cold-working, the base's shape changes (expanding laterally) and its mechanical properties are optimized for attachment, eliminating the need for thermal processing parameters.
2Adaptability or versatility
If multiple tool bodies are used to accommodate different cutting requirements, then various segment configurations can be achieved, but the device complexity and production costs increase significantly
Solution Approach 1:
The patent creates a universal tool body design with standardized notches that can accommodate different diamond segment configurations. The cold-working attachment method allows the same tool body to be used with various segment types, sizes, and arrangements by simply changing the segments themselves, not the tool body. This multi-functional approach reduces the number of different tool bodies needed.
Solution Approach 2:
The patent divides the tool into modular components: a standardized tool body with notches and replaceable diamond segments with bases. This segmentation allows flexible reconfiguration by swapping segments while keeping the tool body, enabling adaptability without increasing overall device complexity.
3Strength
If thermal processes are used for segment attachment, then secure fastening is achieved, but the operations become very labour-intensive and expensive
Solution Approach 1:
The patent replaces complex thermal processes (heating, brazing/welding, cooling, and subsequent substrate restoration) with a simpler mechanical cold-working process. The base is inserted into the notch and then cold-worked using pressing, crimping, or swaging operations, which are less labor-intensive and expensive than thermal processes. This eliminates the need for specialized heating equipment and skilled thermal processing operators.
4Strength
If diamond segments are brazed or welded to the substrate, then they can be firmly attached, but there is a risk that the diamond elements will be damaged during the heating operation
Solution Approach 1:
The patent replaces the thermal attachment process (brazing/welding) with a mechanical cold-working process. The base is inserted into the notch and then cold-worked to expand laterally, creating friction and mechanical interlocking with the notch walls. This eliminates thermal exposure entirely, removing the risk of thermal damage to diamond segments while achieving firm attachment through mechanical means.
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 reduces production costs and complexity by enabling efficient, cold-state assembly without damaging diamond segments, allowing for various segment configurations and extended tool life through easy reconditioning, while maintaining mechanical resistance and cutting performance.
Implementation Method 1
two lateral sides of the base can be pressed at to give a deformation of the base making it expand in other directions and fill the notch
Implementation Method 2
fixed to the tool body through mechanical crimping or pressing
Implementation Method 3
diamond segments manufactured by sintering
Data Source
Figure 1~5
Figure 6~10
AI summary
The invention relates to a diamond tool comprising a tool body (1, 2, 3) provided with diamond segments (4) manufactured by sintering and each segment comprising at least one diamond part (5) and a base part (6), or base (6), which base (6) is fixed to the tool body (1, 2, 3), so that the diamond part protrudes from a cutting edge (10) of the tool body in a protruding direction. More specifically a number of notches (7) are arranged to cross through the cutting edge (10) in a lateral direction compared to the protruding direction, and at least one, and preferably all, of the diamond segments (4) are fixed to the tool body (1, 2, 3) through attachment of the base (6) of the diamond segment to at least one notch (7) by fixing methods comprising a base deforming force applied in a lateral direction to the base (6), compared to the protruding direction.