Laser Machining of Multi-Layer Cutting Inserts Without Edge Offsets
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Solution Overview
Problem
Existing methods for machining cutting inserts with multi-layer materials using lasers often result in inaccuracies due to mismatched layer thicknesses and material properties, leading to offsets between the hard material layer and the base material, which affect the quality of the cutting edge and surface geometry.
Innovation Solution
A method that involves predetermining a machining program based on ablation geometry, measuring the actual layer thickness of a multi-layer workpiece blank, and modifying the program to ensure consistent removal geometry, allowing for real-time adaptation of laser parameters and guidance to match the current layer thickness, thereby preventing offsets and improving surface and edge quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If laser machining is performed using a predetermined machining program based on nominal layer thickness, then the machining process can be automated and executed efficiently, but the actual layer thickness variations cause offsets between the hard material layer and base material, degrading the quality of the cutting edge and surface geometry
Solution Approach 1:
The invention performs preliminary measurement of the actual layer thickness of the hard material layer before laser machining begins. This preliminary action allows the machining program to be adjusted in advance based on the measured thickness, ensuring that the laser ablation process removes the correct amount of material and prevents offsets at the interface between the hard material layer and base material, thereby maintaining high cutting edge quality while preserving automated machining efficiency
Solution Approach 2:
The invention implements a feedback mechanism where the measured actual layer thickness is used to modify the machining program parameters. The control unit automatically adjusts the ablation geometry and laser processing parameters based on the measured thickness value, creating a closed-loop control system that adapts the predetermined machining program to the actual workpiece conditions, thus eliminating offsets and improving manufacturing precision without sacrificing productivity
2Manufacturing precision
If the laser parameters are adjusted to accommodate varying layer thicknesses, then the quality of the free surface and edge geometry improves, but the complexity of the machining process increases due to real-time parameter adaptation
Solution Approach 1:
The control unit automatically modifies the machining program based on the measured layer thickness, adjusting laser parameters such as power, pulse duration, and ablation depth in a systematic feedback loop. This automated parameter adaptation eliminates the need for manual intervention and complex manual adjustments, maintaining surface and edge quality while managing process complexity through automation
Solution Approach 2:
The invention systematically changes laser processing parameters (power, pulse duration, feed rate, ablation depth) based on the measured layer thickness. These parameter changes are pre-programmed and automatically applied by the control unit, allowing the system to adapt to thickness variations without requiring complex real-time decision-making or additional hardware, thus improving quality while keeping the process manageable
3Loss of time
If samples are separated from larger blanks before machining, then the machining setup time is reduced, but the measurement of actual layer thickness must be performed separately, adding to the overall process complexity
Solution Approach 1:
The invention merges the measurement function and machining function into a single integrated system. The measuring device and laser machining device are combined in one setup, allowing the actual layer thickness to be measured directly on the separated sample without requiring separate measurement and machining operations. This integration eliminates additional setup steps and reduces overall process complexity while maintaining reduced setup time from sample separation
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 approach ensures precise adaptation of the machining program to the current layer thickness, significantly improving the quality of the free surface and edge geometry by preventing or reducing the formation of offsets, even with irregular coating variations, and enhancing the service life of cutting tools.
Implementation Method 1
a method for machining a multi-layer workpiece blank (3) by means of a laser beam (9a)
Data Source
AI summary
The invention relates to a method for machining a multi-layer workpiece blank (3) by means of a laser beam, comprising the following steps: specifying a machining program for machining the workpiece blank according to an ablation geometry in order to generate a desired edge and/or surface geometry (13) using a laser machining device; tensioning the workpiece blank in the laser machining device and positioning the workpiece holder in a measuring position; measuring a thickness of at least one of the layers of the multi-layer workpiece blank (3); modifying the machining program in order to machine the multi-layer workpiece blank (3) according to the measured layer thickness with an consistent ablation geometry; and machining the tensioned workpiece blank (3) using the modified machining program via a laser of the laser machining device in order to generate the desired edge and/or surface geometry (13) with a cutting edge (12). The invention also relates to a correspondingly configured device.