Machining Segment Side-Surface Projections for Wear Resistance
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Solution Overview
Problem
Machining segments for core drill bits, saw blades, and cut-off grinding chains experience increased wear on side surfaces due to friction with concrete substrates, particularly because second hard material particles are fully embedded in the matrix material, requiring sharpening to expose them and reducing tool effectiveness.
Innovation Solution
A method involving a three-stage process to produce machining segments with a green body composed of a first matrix material, first hard material particles arranged in a defined pattern, and second hard material particles, using films with lower hardness than the matrix material to create projections on side surfaces during compaction, eliminating the need for re-working and utilizing conventional tool components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If second hard material particles are admixed with the first matrix material to reduce wear on side surfaces, then wear resistance is improved, but the hard material particles become completely embedded in the matrix material requiring additional sharpening operations
Solution Approach 1:
The patent applies preliminary action by arranging the second hard material particles in a defined particle pattern during the green body construction stage, positioning them to protrude from the side surfaces before compaction. This preliminary arrangement ensures that after compaction and sintering, the particles automatically protrude from the side surfaces without requiring additional sharpening operations, thus resolving the contradiction between wear resistance and productivity
2Reliability
If hard material particles are arranged in a defined particle pattern, then wear properties are improved, but the production process complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the hard material particles into two distinct groups: first hard material particles arranged in a first defined particle pattern and second hard material particles arranged in a second defined particle pattern. This segmentation allows each group to serve specific functions (cutting vs. wear protection) while maintaining organized structures that can be achieved through systematic arrangement methods rather than random distribution, thus improving wear properties without excessive complexity
Solution Approach 2:
The patent applies local quality by creating different particle arrangements in different regions of the machining segment. The first hard material particles are arranged in a first defined particle pattern suitable for cutting action, while the second hard material particles are arranged in a second defined particle pattern optimized for wear resistance on side surfaces. This localized optimization allows each region to have the specific properties needed for its function, improving overall wear properties while maintaining a structured production approach
3Reliability
If machining segments are produced with protruding hard material particles on side surfaces, then wear resistance is improved, but conventional compaction methods cannot achieve the required particle exposure
Solution Approach 1:
The patent applies preliminary action by pre-arranging the second hard material particles in a defined particle pattern during green body construction, positioning them to protrude from the green body surface before compaction. This preliminary arrangement ensures that when conventional compaction is applied, the particles maintain their protruding position and become exposed on the side surfaces of the sintered machining segment, thus achieving wear resistance using standard compaction equipment
Solution Approach 2:
The patent applies self-service by designing the green body structure so that the second hard material particles naturally protrude from the green body surface during construction, and this protruding configuration is maintained through conventional compaction and sintering processes. The particle arrangement itself serves the function of creating the desired surface geometry without requiring special compaction tools or additional post-processing operations, thus improving ease of manufacture
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 method effectively reduces wear on side surfaces by creating projections of second hard material particles on machining segments, enhancing their durability and performance without requiring additional processing steps, such as sharpening, and allowing for conventional tool usage.
Implementation Method 1
when compacting the green body, a first film of a film material is arranged between the first press punch and the green body and a second film of the film material is arranged between the second press punch and the green body, the film material having a hardness which is less than the hardness of the first matrix material
Data Source
AI summary
Method for producing a machining segment (51) for a machining tool from a powdered or granular first matrix material (56), first hard material particles (57), which are arranged according to a defined first particle pattern, and second hard material particles (58), which are arranged according to a defined second particle pattern, the machining segment being connected by an underside (61) to a basic body of the machining tool. The machining segment (51) has on the side surfaces a projection of the second hard material particles (58) with respect to the first matrix material (56).