Flexible Insert Cutting for Complex Metal and Composite Paths

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Current cutting technologies are inadequate for accurately cutting complex forms in hard metal or composite materials with large dimensions and complex trajectories, leading to inefficiencies in machining time and material waste.

Innovation Solution

A cutting device with a flexible or articulated support and a guide forming a trajectory with changes in direction, featuring a cutting insert with a protruding edge, allows for cutting along complex paths and large dimensions, including sinusoidal trajectories, while minimizing material loss.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If blade or chain saw devices are used for cutting, then cutting speed is improved, but they are not suitable for hard metal or composite materials and complex trajectories

Engineering Contradiction:

Improvecutting speedVSAvoidsuitability for hard materials and complex trajectories

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The cutting device is divided into multiple cutting inserts arranged along a flexible support (chain), each insert capable of independent cutting action. This segmentation allows the system to handle complex trajectories by distributing cutting tasks across multiple elements while maintaining high productivity through parallel cutting operations.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention changes the cutting parameters by using hard cutting inserts (such as diamond-tipped or carbide inserts) instead of traditional blade teeth, enabling cutting of hard metal and composite materials. The flexible support structure also allows parameter changes in trajectory complexity, moving from simple linear cuts to complex curved paths.

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If electro-erosion or wire cutting is used, then complex forms can be machined, but cutting depth is limited to ≤300 mm and machining time increases

Engineering Contradiction:

Improvecomplex forms capabilityVSAvoidmachining time

Core Design Contradiction:

Manufacturing precisionVSDuration of action of moving object

Solution Approach 1:

The invention replaces electro-erosion and wire cutting mechanisms with a mechanical cutting system using hard cutting inserts. This substitution enables deeper cutting capabilities (exceeding 300 mm) while maintaining the ability to machine complex forms through the flexible support structure that can follow complex trajectories.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The cutting inserts are pre-configured on the flexible support structure before cutting begins, allowing the system to plan and execute complex trajectories in advance. This preliminary arrangement of cutting elements enables efficient deep cutting operations without the time constraints of electro-erosion methods.

Inventive Principle:

Principle #10Preliminary action

3Loss of substance

If conventional cutting methods are used, then material waste is produced, but machining time increases and material loss reaches up to 30%

Engineering Contradiction:

Improvematerial wasteVSAvoidmachining time

Core Design Contradiction:

Loss of substanceVSProductivity

Solution Approach 1:

The cutting inserts are positioned at specific locations along the flexible support to follow the exact contour of the desired part geometry. This localized precision cutting minimizes material waste by removing only the necessary material, while the efficient cutting action maintains high productivity without excessive machining time.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The flexible support structure allows dynamic adaptation to complex part geometries, enabling the cutting path to closely follow the desired final shape. This dynamic capability reduces material waste by eliminating the need for excessive material removal, while the efficient mechanical cutting maintains high productivity.

Inventive Principle:

Principle #15Dynamics

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 significantly reduces machining time and material waste by enabling precise cutting of complex forms over large dimensions with a higher chip production rate, saving up to 30% of material compared to prior art methods.

Implementation Method 1

a cutting insert forming the cutting element, comprising a protruding cutting edge arranged to perform the cutting in a normal direction in relation to said blank

Methodology Applied

Scientific EffectMechanical cutting: Abrasion

Data Source

PatentUS11370139B2Device and method for cutting parts consisting of a metal or composite material and parts produced with such a method

Publication Date: 2022.06.28 MECACHROME FRANCE

AI summary

The invention relates to a device, a method and an assembly of parts produced by cutting in a block B of metal or composite material, following a determined trajectory. The device comprises a guide (3) forming said trajectory and a support (chain 9) mounted in the guide in a sliding manner, comprising a lateral blank (23) provided with at least one cutting plate (24) comprising a protruding cutting edge (25) arranged so as to carry out the cutting in a normal direction (26) in relation to the blank.