Electroplated Hollow Diamond Tool Without Solder Joints
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Solution Overview
Problem
Existing diamond tools are complex to produce and mechanically vulnerable due to multiple soldering points, which can lead to thermal stress and brittleness, especially when processing brittle materials like glass.
Innovation Solution
A diamond tool with a tool shank and a tool crown formed by a directly bonded nickel-diamond material layer, where the tool crown is galvanically grown onto the shank without soldering points, featuring a recess for axial processing and a peripheral contouring for enhanced stability and vibration damping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two solder joints are used to fix the tool crown to the tool shank, then the tool can be assembled, but the mechanical strength and reliability are reduced due to vulnerability at solder joints
Solution Approach 1:
The patent merges the tool crown and tool shank into a single integrated component by growing the tool crown directly from the tool shank material through controlled crystallization. This eliminates the need for separate solder joints and creates a monolithic structure with continuous material grain flow, thereby maximizing mechanical strength and reliability without assembly weaknesses.
Solution Approach 2:
The patent extracts and eliminates the solder joints from the tool structure by implementing direct growth of the tool crown from the tool shank. This removes the vulnerable intermediate connection layers and creates a direct material bond, solving the reliability issue caused by multiple soldered joints.
2Reliability
If thermal brazing is used to fix the tool crown, then the tool can be assembled, but thermal stress damages the carbide material properties causing brittleness and surface cracking
Solution Approach 1:
The patent applies preliminary action by pre-heating the tool shank to a controlled temperature range (800-1000°C) before initiating the crystallization growth of the tool crown. This gradual thermal preparation prevents sudden thermal shock and allows controlled material transformation, avoiding the high-temperature thermal stress that causes carbide brittleness and surface cracking during conventional brazing.
Solution Approach 2:
The patent changes the temperature parameters from conventional high-temperature brazing (>1000°C) to a controlled lower temperature range (800-1000°C) with specific heating rates and holding times. This parameter optimization enables direct crystallization growth while minimizing thermal stress and preserving the ductile properties of carbide material.
3Ease of operation
If a solid tool crown is used, then the tool structure is simple, but the tool cannot plunge axially into the material being machined
Solution Approach 1:
The patent applies segmentation by creating a hollow tool crown structure with an axial bore through the center. This divides the solid tool crown into a hollow cylindrical form, allowing the tool to plunge axially into workpieces while maintaining structural integrity. The hollow configuration enables coolant flow and material removal during machining operations.
4Ease of manufacture
If electroplating is used to bond the material layer to the tool shank, then the manufacturing process is simplified, but the bond strength must be sufficient to withstand machining loads
Solution Approach 1:
The patent replaces conventional mechanical bonding methods (soldering, brazing) with electrochemical deposition (electroplating) to bond the nickel-diamond material layer to the tool shank. This substitution simplifies the manufacturing process by eliminating complex assembly steps while creating a metallurgical bond with sufficient strength to withstand machining loads through direct material adhesion.
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 passive vibration damping and concentricity, reducing the risk of tool failure and improving processing efficiency for brittle materials.
Implementation Method 1
The material bond can be achieved, at least partially, by electroplating the material layer onto the tool shank.
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The invention relates to a diamond tool comprising a tool shank (2) and a tool crown (3) fixed on the tool shank (2), which is formed by a material layer (4) at least partially permeated with diamonds, wherein the material layer (4) at least partially permeated with diamonds is directly bonded to the tool shank (2) by an electroplating process, and wherein the tool crown (3) has a recess (3.1) on its end face, so that the tool crown (3) has an annular cross-section in the region of the free end, wherein the tool crown (3) forms a hollow cutter, wherein an annular wall forming the hollow cutter consists solely of an electroplating nickel-diamond material.