Laser Machining Rotary Tool Cutting Bodies
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Solution Overview
Problem
Existing methods for machining rotary tools with hard cutting bodies, such as those made of cubic crystalline boron nitride or diamond, are inefficient and material-intensive, leading to inadmissible tolerance deviations and reduced cutting effectiveness due to the difficulty in accurately shaping and sharpening these tools without damaging their cutting edges.
Innovation Solution
A method and device that systematically identify and remove individual cutting bodies on a rotary tool using a laser beam, focusing on specific target variables to maintain the tool's desired shape and cutting characteristics, ensuring the actual enveloping surface lies within specified tolerances while minimizing material removal and preserving cutting efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional abrasive methods or crushing are used to finish rotary tools with hard cutting bodies, then the outer contour can be adapted to the target enveloping area, but the sharp tips and edges of the cutting bodies are removed and the cutting effect is negatively influenced
Solution Approach 1:
The patent replaces mechanical abrasive methods and crushing with a laser beam system. The laser beam selectively removes material from the rotary tool surface without mechanical contact, thereby avoiding damage to the cutting body tips and edges while still achieving the target contour accuracy.
Solution Approach 2:
The patent changes the physical state and properties of the laser beam during machining - adjusting parameters such as laser power, pulse duration, and beam focus to selectively remove binding material while preserving the cutting bodies. This allows precise control over material removal without compromising cutting body integrity.
2Loss of substance
If laser beam is used for machining rotary tools with tangential focusing, then material can be removed, but the method is extremely time-consuming and creates large tangential surfaces that reduce cutting effect
Solution Approach 1:
The patent employs dynamic control of the laser beam - the beam is moved along the rotary tool surface in a controlled manner, and the focusing position is dynamically adjusted between radial and tangential orientations. This dynamic approach allows efficient material removal while minimizing the creation of large tangential surfaces.
Solution Approach 2:
The patent changes the laser beam orientation parameter dynamically during machining. By switching between radial and tangential focusing modes and adjusting beam movement speed, the process achieves optimal balance between material removal efficiency and productivity, avoiding the time-consuming nature of purely tangential machining.
3Manufacturing precision
If crushing tool is used to machine rotary tools, then the working surface can be adapted two-dimensionally, but the method is limited to the accuracy of the crushing tool and requires porous or rough binding material
Solution Approach 1:
The patent replaces the mechanical crushing tool with a laser beam system. This substitution eliminates the accuracy limitations of mechanical tools and removes the requirement for porous or rough binding materials, as the laser can selectively remove material from any binding material type with high precision.
Solution Approach 2:
The patent utilizes the adjustable parameters of the laser beam (power, pulse duration, focus position) to adapt the machining process to different binding material types. This provides universal applicability across various binding materials without requiring specific material properties like porosity.
4Manufacturing precision
If cutting bodies are removed to adapt the enveloping surface, then the target dimensions can be reached, but the material usage of the cutting bodies must be minimized as they are expensive
Solution Approach 1:
The patent uses a laser beam to selectively remove only the binding material and minimal amounts of cutting body material. This precise control allows achieving target dimensions while minimizing cutting body material loss, as the laser can be focused to remove material layer by layer without excessive removal.
Solution Approach 2:
The patent employs a feedback-controlled machining process where the laser beam removes material in controlled increments, allowing continuous monitoring and adjustment to reach target dimensions with minimal material removal. This feedback mechanism ensures that cutting body material is preserved while achieving the required precision.
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 allows for precise, economical machining of rotary tools by selectively removing cutting bodies based on measured deviations, ensuring the tool's desired shape and characteristics are achieved with minimal material loss and improved cutting performance.
Implementation Method 1
a laser beam L, which is focused towards a machining location 36 on the rotary tool 21, is created by a laser device 35
Data Source
AI summary
A rotary tool (21) working surface (23) includes a plurality of cutting bodies (24). The rotary tool (21) can be driven about a rotational axis (R). The actual enveloping surface (HF) of the working surface (23) is ascertained by an optical measuring arrangement (29). At least one other target variable (GS) is detected, which describes a microscopic parameter of the working surface (23). The actual variable (GI) corresponding to each specified target variable (GS) is detected by the measuring arrangement (29), and the deviation between the target variable (GS) and the actual variable (GI) is determined. If the actual enveloping surface (HF) lies outside of a specified target enveloping area (HR) or if a deviation (D) between an actual variable (GI) and the corresponding target variable (GS) is unacceptably large, selected first and/or second cutting bodies (24a, 24b) are machined and/or removed by a laser device (35).