Doped Diamond Stop Layer for Machining Tool Wear Detection

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Diamond-coated machining tools experience wear issues during high-speed operations, leading to tool damage and potential damage to the workpiece and machine, necessitating an early detection method for diamond layer wear to prevent such incidents.

Innovation Solution

A method involving a doped polycrystalline diamond layer on a metal surface to continuously detect the wear of an undoped polycrystalline diamond layer using physical parameters like electrical conductivity, allowing for timely intervention before tool failure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Duration of action of stationary object

If a diamond layer is applied to increase wear resistance, then the service life of the tool is extended, but the tool cannot be monitored for wear and may fail suddenly causing damage

Engineering Contradiction:

Improveservice life of toolVSAvoidpredictability of tool failure

Core Design Contradiction:

Duration of action of stationary objectVSReliability

Solution Approach 1:

A doped diamond layer with different electrical properties is introduced as an intermediary between the undoped diamond functional layer and the metal substrate. This intermediary layer enables electrical conductivity monitoring to detect wear of the undoped diamond layer, providing early warning before tool failure occurs.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The electrical conductivity of the doped diamond layer is continuously monitored during tool operation. As the undoped diamond layer wears away, the electrical properties of the doped layer change, providing feedback about the wear state of the functional layer, allowing for timely tool replacement before failure.

Inventive Principle:

Principle #23Feedback

2Reliability

If a doped diamond layer is used for wear detection, then early warning of tool wear is enabled, but the tool structure becomes more complex

Engineering Contradiction:

Improvedetectability of wearVSAvoidstructure of diamond coating

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The wear detection function is merged with the existing diamond coating structure by doping a diamond layer with foreign atoms. This creates a multi-functional coating where the doped diamond layer serves both as part of the protective coating and as a sensor element for wear detection, eliminating the need for separate sensing components.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The electrical conductivity parameter of the diamond layer is changed through doping with foreign atoms. This parameter change enables the layer to respond to wear mechanically by changing its electrical properties, allowing for non-contact electrical monitoring of the wear state without adding structural complexity.

Inventive Principle:

Principle #35Parameter changes

3Duration of action of stationary object

If the undoped diamond layer is made thicker to extend service life, then wear resistance is improved, but detection of wear degree becomes more difficult

Engineering Contradiction:

Improveservice life of toolVSAvoidwear detection sensitivity

Core Design Contradiction:

Duration of action of stationary objectVSDifficulty of detecting and measuring

Solution Approach 1:

The wear detection is shifted from direct mechanical measurement of the thick undoped diamond layer to electrical property measurement of the underlying doped diamond layer. This dimensional change from mechanical to electrical domain enables sensitive detection of wear through the thick functional layer by monitoring changes in the doped layer's electrical conductivity.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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

Enables early detection of diamond layer wear, preventing tool and workpiece damage by stopping the tool when wear thresholds are exceeded, thereby extending tool life and ensuring operational safety.

Implementation Method 1

detecting a wear state of the undoped diamond layer on the basis of a change in at least one physical parameter of the doped diamond layer, in particular on the basis of a change in electrical conductivity, Hall effect or capacitance

Methodology Applied

Scientific EffectElectrical conductivity: Conduction (electrical)

Implementation Method 2

Methodology Applied

Scientific EffectHall effect: Hall Effect

Data Source

PatentUS10974360B2Use of a diamond layer doped with foreign atoms to detect the degree of wear of an undoped diamond function layer of a tool

Publication Date: 2021.04.13 GUEHRING KG

AI summary

A first diamond layer made of polycrystalline diamonds and doped with foreign atoms, is arranged on a metal surface of a machining tool, and is used to detect the degree of wear of an undoped polycrystalline second diamond layer, which is arranged on the doped diamond layer and forms a functional region of the machining tool, wherein at least one physical parameter is detected continuously or periodically during operation of the tool, and wherein a change in the parameter indicates the degree of wear of the undoped second diamond layer. The doped diamond layer forms an “intelligent stop layer” for the tool because as a result of change in the transition from the undoped to the doped layer, the conductivity of the system changes, for example, and this change can be used to form a stop signal for the machine drive before the tool and the machined workpiece are damaged.