Two-Phase Laser Machining for Diamond Coated Cutting Tools

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Solution Overview

Problem

Current laser machining methods for producing cutting tools with diamond coatings face challenges in achieving both high accuracy and speed, particularly when dealing with thick PKD diamond coatings that require significant material removal, as they either result in inaccurate optical beam guidance or prolonged mechanical guidance.

Innovation Solution

A two-phase laser machining method is introduced, where the first phase uses optical beam guidance for rapid removal of bulk material with less precision, and the second phase employs mechanical beam guidance for precise removal near the final surface, allowing for a combination of high accuracy and efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If optical beam guidance is used for rapid material removal, then productivity is improved, but manufacturing precision deteriorates

Engineering Contradiction:

Improvematerial removal speedVSAvoidcutting edge accuracy

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The machining process is divided into two distinct phases: a first phase using optical beam guidance for rapid bulk material removal, and a second phase using mechanical beam guidance for precise final shaping. This segmentation allows each method to be optimized for its specific function, resolving the contradiction between speed and precision.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system dynamically switches between two different beam guidance modes (optical and mechanical) depending on the machining stage. The transition from optical to mechanical guidance is not static but adapts to the remaining material thickness and precision requirements, enabling optimal performance throughout the process.

Inventive Principle:

Principle #15Dynamics

2Manufacturing precision

If mechanical beam guidance is used for high precision machining, then manufacturing precision is improved, but productivity deteriorates

Engineering Contradiction:

Improvecutting edge accuracyVSAvoidproduction time

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The optical beam guidance performs preliminary action by removing the majority of excess diamond material quickly in the first phase. This preliminary removal reduces the workload for the subsequent precision machining phase, allowing mechanical guidance to focus only on fine adjustments and final surface finishing.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The optical guidance performs excessive material removal beyond what is strictly necessary for final dimensions, creating a larger margin for the precision phase. This partial completion approach allows the slower mechanical guidance to operate on reduced material volumes, improving overall efficiency.

Inventive Principle:

Principle #16Partial or excessive action

3Loss of substance

If thick PKD diamond coatings are removed using conventional laser machining, then the required material removal is achieved, but production time is prolonged

Engineering Contradiction:

Improvediamond coating removalVSAvoidproduction time

Core Design Contradiction:

Loss of substanceVSLoss of time

Solution Approach 1:

The patent replaces conventional mechanical machining methods with a hybrid laser-based system that combines optical and mechanical beam guidance. This substitution enables rapid removal of thick diamond coatings through the optical phase, dramatically reducing production time compared to traditional mechanical removal methods.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 enables the rapid and accurate manufacture of workpieces by dynamically adjusting the laser beam guidance, significantly reducing production time while maintaining the required precision, especially for cutting tools with thick diamond coatings.

Implementation Method 1

moving a laser beam over the exposed workpiece surface to evaporate and/or combust workpiece material

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Implementation Method 2

to evaporate and/or combust workpiece material

Methodology Applied

Scientific EffectEvaporation: Evaporation

Implementation Method 3

guidance of the laser beam is made via optical elements (in particular adjustable mirrors) inside the laser tool

Methodology Applied

Scientific EffectOptical reflection: Reflection

Data Source

PatentUS10201928B2Method and device for machining a workpiece, more particularly for producing cutting tools

Publication Date: 2019.02.12 SAUER LASERTEC

AI summary

A method for machining a workpiece by means of a laser beam, in which material of the workpiece is removed layer-by-layer according to predetermined definitions to produce a workpiece by traversing the exposed workpiece surface in lengths across the entire surface with a laser beam in order to vaporize and/or combust workpiece material. In a first material removal phase, the laser beam is guided relative to the workpiece over the workpiece surface by adjustable mirrors inside the laser tool, more particularly without mechanical control axes being moved to adjust the relative position between the laser tool and the workpiece. In a second material removal phase, the laser beam is guided relative to the workpiece over the workpiece surface by means of one or more control axes of the machine, the focal length being variably adjustable by means of a variable optical unit.