Powder Bed Fusion Machining Segments for Dry Concrete Cutting
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Solution Overview
Problem
Machining tools designed for wet concrete machining are not suitable for dry machining, as they produce abrasive concrete sludge that self-sharpens the segments, but without this sludge, hard material particles become dull, reducing machining rate and service life in dry conditions.
Innovation Solution
A method involving a powdered supporting material with a higher melting temperature than the matrix material, where hard material particles are arranged in a defined pattern within the supporting material, and fused using powder bed fusion to create machining segments suitable for dry concrete machining, eliminating the need for additional processing like sintering or hot pressing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If machining segments are designed for wet machining with similar wear rates of matrix material and hard material particles, then self-sharpening occurs through abrasive concrete sludge, but in dry machining the hard material particles quickly become dull and machining rate drops
Solution Approach 1:
The patent applies local quality by creating a differentiated two-zone structure within the machining segment: a machining zone with high hard material particle concentration for cutting, and a neutral zone with different matrix material properties for structural support. This local differentiation allows the machining zone to maintain high machining rate while the overall segment achieves extended service life through optimized material distribution and wear characteristics.
Solution Approach 2:
The patent employs composite materials by combining matrix material with hard material particles (such as diamond or cubic boron nitride) to create a machining segment with superior wear resistance and machining performance. The composite structure enables the segment to withstand dry machining conditions while maintaining both high machining rate and extended service life through the synergistic properties of the constituent materials.
2Manufacturing precision
If hard material particles are arranged in a defined particle pattern in the matrix material, then machining performance is optimized, but the production process becomes more complex
Solution Approach 1:
The patent applies preliminary action by pre-arranging hard material particles in a defined pattern within the green body before sintering. This pre-positioning ensures that after sintering, the hard material particles maintain their optimized spatial arrangement for machining performance, achieving high manufacturing precision without requiring complex post-processing or specialized sintering equipment to maintain particle patterns.
3Strength
If machining segments are produced by traditional methods requiring sintering or hot pressing, then hard material particles are secured in the matrix, but additional processing steps increase manufacturing complexity and time
Solution Approach 1:
The patent applies merging by combining the particle arrangement step and the sintering process into a integrated workflow where hard material particles are positioned in the green body before sintering. This consolidation ensures secure bonding of particles to the matrix through the sintering process itself, eliminating the need for separate particle fixation steps and reducing overall manufacturing complexity while maintaining strong particle-matrix bonding.
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 produces machining segments with a high machining rate and extended service life in dry concrete machining by securely fixing hard material particles and reducing matrix material wear, enhancing the tool's performance in dry conditions.
Implementation Method 1
applying a powdered supporting material as a supporting layer, wherein the melting temperature of the supporting material is higher than the melting temperature of the first matrix material
Implementation Method 2
applying a first layer of the first matrix material to the first hard material particles and the supporting material and fusing the first layer by means of a powder bed fusion method
Implementation Method 3
performing a sequence of a plurality of steps, which is performed N times, N≥1, wherein, in a first step of the sequence, a layer of the first matrix material is applied to the layer structure, and in a second step of the sequence, the layer of the first matrix material is fused by means of the powder bed fusion method and connected to the layer structure
Data Source
AI summary
A method for producing a machining segment from a first powdered matrix material and first hard material particles arranged according to a defined first particle pattern, includes: applying a powdered supporting material as a supporting layer with a melting temperature higher than the first matrix material, arranging the first hard material particles according to the defined first particle pattern in the supporting material with a depth of penetration, applying a first layer of the first matrix material to the first hard material particles and the supporting material and fusing the first layer by a powder bed fusion method, and performing a sequence of a plurality of steps N times, N≥1, wherein, in a first step of the sequence, a layer of the first matrix material is applied to the layer structure, and in a second step of the sequence, the layer of the first matrix material is fused by the powder bed fusion method and connected to the layer structure.