Diamond-Coated Rotary Cutting Tool for Shoulder Chipping Resistance
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Solution Overview
Problem
In double angle drills, a high load applied to the shoulder portion during rotary cutting can cause chipping, which is not effectively addressed by existing technologies.
Innovation Solution
A rotary cutting tool with a base material coated by a first diamond layer covering the body and shoulder portions and a second diamond layer covering the head portion, but not the body, increasing the total diamond layer thickness near the shoulder to enhance strength and wear resistance, thereby reducing chipping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a single diamond layer is applied to the shoulder portion, then the manufacturing process is simple, but the strength and wear resistance are insufficient under high load
Solution Approach 1:
The diamond coating is divided into two separate layers: a first diamond layer covering the shoulder portion and a second diamond layer covering the head portion. This segmentation allows each layer to be optimized for its specific functional requirements, with the first layer providing enhanced strength and wear resistance at the high-load shoulder region, while the second layer protects the head portion.
Solution Approach 2:
The patent applies different diamond layer configurations to different regions of the cutting tool. The shoulder portion receives a first diamond layer specifically designed to withstand high loads, while the head portion receives a second diamond layer. This local differentiation ensures that each region has the appropriate protective properties for its specific operational conditions.
2Reliability
If a single diamond layer is used across all portions, then the manufacturing process is simple, but chipping occurs under high load in the shoulder portion
Solution Approach 1:
The diamond coating is divided into two separate layers: a first diamond layer covering the shoulder portion and a second diamond layer covering the head portion. This segmentation allows each layer to be optimized for its specific functional requirements, with the first layer providing enhanced strength and wear resistance at the high-load shoulder region, while the second layer protects the head portion.
Solution Approach 2:
The patent applies different diamond layer configurations to different regions of the cutting tool. The shoulder portion receives a first diamond layer specifically designed to withstand high loads, while the head portion receives a second diamond layer. This local differentiation ensures that each region has the appropriate protective properties for its specific operational conditions.
3Strength
If the diamond layer is thin, then the manufacturing cost is lower, but the wear resistance is insufficient for high-load cutting operations
Solution Approach 1:
The patent applies different diamond layer configurations to different regions of the cutting tool. The shoulder portion receives a first diamond layer specifically designed to withstand high loads, while the head portion receives a second diamond layer. This local differentiation ensures that each region has the appropriate protective properties for its specific operational conditions.
Solution Approach 2:
The patent transitions from a single-layer to a multi-layer diamond coating structure, adding a dimensional aspect to the coating design. By stacking the first diamond layer on the shoulder portion and the second diamond layer on the head portion, the total protective thickness is increased in critical areas without uniformly thickening the entire coating, thus improving wear resistance where needed while controlling overall complexity.
Data Source
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AI summary
A rotary cutting tool includes a base material, a first diamond layer, and a second diamond layer. The base material includes a head portion, a body portion, and a shoulder portion defining a boundary portion between the head portion and the body portion. The first diamond layer covers the body portion and the shoulder portion and exposes the head portion. The second diamond layer covers the head portion, is provided on the first diamond layer in the shoulder portion, and does not cover the body portion.