Disk-Shaped Cutting Tool With Integrated Grinding for Burr-Free Cuts

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Solution Overview

Problem

Existing machining processes for workpieces often result in surfaces with high roughness, burrs, and material damage due to coarse cutting edges, requiring additional grinding or polishing steps to meet quality standards, and tool wear is typically checked visually, leading to inefficiencies and uneven results.

Innovation Solution

A disk-shaped cutting tool with radially inner grinding and polishing agents and a wear indicator that allows for simultaneous cutting, grinding, and polishing, using geometric and kinematic properties to widen the cutting gap and provide real-time wear feedback, enabling efficient and precise machining without separate processes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If cutting processes use rotating tools with coarse cutting edges for high cutting performance, then material removal efficiency is improved, but surface quality deteriorates with high roughness, burrs, and material damage

Engineering Contradiction:

Improvecutting performanceVSAvoidsurface quality

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent combines cutting, grinding, and polishing functions into a single integrated tool. The tool features a peripheral cutting region with cutting edges for material removal and axial end surfaces with grinding/polishing agents for surface finishing. This allows simultaneous execution of all three operations in one machining pass, eliminating the need for separate cutting and surface finishing processes.

Inventive Principle:

Principle #5Merging (Combining)

2Manufacturing precision

If cutting and grinding processes are carried out with different tools in successive operations, then each process can be optimized independently, but manufacturing time and complexity increase

Engineering Contradiction:

Improveprocess optimizationVSAvoidmanufacturing time

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The tool is designed as a multi-functional device that performs cutting, grinding, and polishing operations simultaneously. The peripheral region contains cutting edges for separating cuts while the axial end surfaces contain grinding and polishing agents for surface finishing. This universal tool eliminates the need for multiple specialized tools and sequential operations.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Ease of operation

If visual inspection is used to check tool wear, then inspection simplicity is maintained, but detection precision and reliability deteriorate

Engineering Contradiction:

Improveinspection simplicityVSAvoidwear detection accuracy

Core Design Contradiction:

Ease of operationVSMeasurement precision

Solution Approach 1:

The tool incorporates a wear indicator that provides visual feedback about the tool's condition. The wear indicator includes a visible region that changes appearance or becomes visible when the cutting edges or grinding agents reach their wear limit, enabling operators to monitor tool condition without complex inspection equipment while maintaining reliable detection.

Inventive Principle:

Principle #23Feedback

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 solution ensures clean, burr-free cut surfaces with improved surface quality and reduces setup and tool change times by integrating grinding and polishing into the cutting process, while the wear indicator ensures optimal tool utilization, minimizing errors and costs.

Implementation Method 1

using geometric and kinematic properties to widen the cutting gap

Methodology Applied

Scientific EffectGeometric properties: Geometry

Implementation Method 2

cutting processes in a radial working direction are referred to as 'cutting'

Methodology Applied

Scientific EffectAbrasion: Abrasion

Implementation Method 3

the possible processing steps for increasing the surface quality in an axial working direction of a disk-shaped rotating tool are collectively referred to as 'grinding'

Methodology Applied

Scientific EffectGrinding: Abrasion

Data Source

PatentUS20220009014A1Disk-shaped tool and method for machining workpieces, cutting device, and use of a cutting, grinding and polishing disk to produce a surf ace structure on a workpiece

Publication Date: 2022.01.13 KLINGSPOR

AI summary

The invention relates to a disk-shaped cutting tool, to a radial cutting method for machining axially elongated workpieces, to a cutting device and to a use of a disk-shaped cutting tool. A disk-shaped cutting tool according to the invention has defined flexibility and a defined impact. In a radial cutting process according to the invention, lateral deflection of the axially stationary rotating tool brings the tool, by means of the at least one laterally applied grinding and polishing surface, into axial effective contact with the workpiece to be machined. In a cutting device according to the invention, the cutting tool can be moved only radially to machine the workpiece. A use according to the invention of a disk-shaped tool serves the purpose of specimen preparation and subsequent surface analysis on a workpiece cut to length.