Diamond Tool Head With Electroplated Bonding and Recessed Ring
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Solution Overview
Problem
Existing diamond tools with soldering points are complex to manufacture, prone to mechanical damage, and suffer from thermal stress that can make the tool shank brittle and develop surface cracks.
Innovation Solution
A diamond tool design featuring a tool head directly integrally bonded to a cemented carbide tool shank via an electroplated nickel-diamond layer, eliminating soldering joints and utilizing a recessed circular ring form for enhanced mechanical stability and vibration damping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two soldering points are used to connect tool head with tool shank, then the tool head can be fixed to the tool shank, but the production becomes complex and the tool becomes mechanically susceptible to damage
Solution Approach 1:
The patent merges the tool head and tool shank into a single integral structure through direct bonding, eliminating the need for separate soldering points. The tool head is directly bonded to the tool shank, creating a unified structure that reduces manufacturing complexity while maintaining mechanical stability.
Solution Approach 2:
The patent removes the soldering joints from the structure, extracting the problematic connection method. By eliminating the soldering points entirely and replacing them with direct bonding, the patent reduces mechanical susceptibility to damage while simplifying production.
2Reliability
If brazing is used to fix steel body to tool shank, then the tool head can be connected to tool shank, but thermal stress makes tool shank brittle and creates surface cracks
Solution Approach 1:
The patent replaces the thermal brazing process with a mechanical direct bonding method. Instead of using heat and molten filler metal, the tool head is directly bonded to the tool shank through a process that does not involve thermal cycling, thereby avoiding thermal stress and preventing brittleness and surface cracks.
3Strength
If tool head is solid without recess, then structural integrity is maintained, but tool cannot be immersed in material for effective processing
Solution Approach 1:
The patent segments the tool head by creating a recess that divides it into functional zones: a solid rear section for structural integrity and connection, and a hollow front section for material processing. This segmentation allows the tool to maintain strength while enabling immersion processing.
Solution Approach 2:
The patent applies local quality by making different sections of the tool head have different structures. The rear section remains solid for structural support, while the front section has a recessed hollow design for effective material processing, allowing each zone to optimize its function.
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 solution results in a mechanically resilient, easy-to-manufacture diamond tool with high stability and improved concentricity, capable of processing brittle materials like glass with reduced susceptibility to damage and thermal stress issues.
Implementation Method 1
The integral bond can be achieved in particular in that the layer of material is grown by electroplating at least in sections on the tool shank
Data Source
AI summary
A method for producing a tool with a diamond-studded tool head includes the steps of providing a tool shank and fixing a support element to a free end of the tool shank. The method further includes the steps of applying a layer of material interspersed with diamonds at least in sections to the support element and to a section of the tool shank adjoining the support element, and at least partially removing the support element, so that the layer of material interspersed with diamonds forms a tool head which in cross-section has the form of a circular ring and has a front-side recess.