Helical Superhard Rake Face for Continuous Center Cutting Edges
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Solution Overview
Problem
Existing cutting tools with superhard materials face challenges in achieving a helical edge with a helix angle greater than 15° and a continuous center cutting edge, due to limitations in manufacturing techniques which result in reduced cutter rigidity and high production costs.
Innovation Solution
A cutting tool design featuring a green body made of superhard material, mounted on a matrix, allows for the arbitrary control of helix angle and reduces superhard material usage. The green body is machined into a continuous cutting edge with a helical rake face greater than 15°, enabling the formation of a continuous center cutting edge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the tilted patching method is used to form a helical edge with superhard material, then a cutting edge with helix angle can be obtained, but the thickness of the cutter core continuously reduces and rigidity is lost
Solution Approach 1:
The patent applies preliminary action by pre-forming a helical groove in the blank before sintering the superhard material. This allows the superhard material to be deposited along a predetermined helical path, creating a continuous helical cutting edge without requiring iterative patching that would compromise cutter rigidity.
Solution Approach 2:
The patent segments the superhard material application into discrete sections corresponding to different radial positions along the helical groove. Each section is sintered separately and then joined to form a continuous helical structure, allowing precise control over material distribution while maintaining overall cutter integrity.
2Shape
If the helical sintering method is used to fill a blank with helical groove, then a helical superhard edge can be formed, but the shape of the cutter is limited by the shape of the sintered blank and helix angle cannot be arbitrarily controlled
Solution Approach 1:
The patent implements dynamics by making the helix angle a variable parameter that can be adjusted according to different cutting requirements. The method allows the blank to be rotated at different speeds relative to the sintering process, dynamically controlling the helix angle without being constrained by fixed mold geometries.
Solution Approach 2:
The patent applies parameter changes by allowing the helix angle, pitch, and other geometric parameters to be modified through process control rather than being fixed by tooling. This enables the same sintering system to produce cutters with different helical configurations by changing operational parameters such as rotation speed and feed rate.
3Shape
If the overall welding and ablation method is used to weld entire cylindrical superhard material, then a helical groove can be machined, but a large number of superhard material is consumed and production cost is high
Solution Approach 1:
The patent extracts only the necessary amount of superhard material needed for the cutting edge by depositing material selectively along the helical groove path. This avoids the waste inherent in welding entire cylindrical superhard material and then removing excess through ablation, as material is placed only where required for the final geometry.
Solution Approach 2:
The patent uses preliminary action by first creating the helical groove geometry in the blank, then filling only this predefined path with superhard material. This eliminates the need to start with a complete cylindrical superhard material and remove material, instead building only the required structure from the beginning.
4Shape
If patches are used to form a discontinuous helical edge, then a helical edge can be created, but the edge is discontinuous and quality is compromised
Solution Approach 1:
The patent ensures continuity of useful action by depositing and sintering superhard material in a continuous helical path without interruptions or discontinuities. The process maintains continuous material flow and heating along the helical groove, resulting in a seamless cutting edge that eliminates the weak points inherent in patched constructions.
Data Source
AI summary
A green body is provided. The green body is made of a superhard material, is used for being fixed on a matrix so as to be machined into a cutting edge part of a cutter. The green body includes a first side surface and a second side surface. Both the first side surface and the second side surface twist at a set helical angle. After being fixed to the matrix, the green body is machined into an edge part for cutting, such as a main cutting edge and a center cutting edge located on the green body made of a same superhard material. The green body is applied to machining the cutting edge of the cutter. A rotating center has a continuous and intact center cutting edge formed by a superhard material.