Multi-Edge Cutting Tool Fabrication Using Periodic Laser Scanning
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for creating periodic fine grooves using monocrystalline diamond tools are inefficient due to the single-point nature of these tools, and forming multiple cutting edges with focused ion beams increases tool manufacturing costs.
Innovation Solution
A method involving pulsed laser grinding to scan a cylindrical irradiation region with periodic scanning paths on both the flank and rake faces of a diamond-coated workpiece, forming multiple cutting edges arranged in line, which reduces manufacturing costs and enhances machining efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a monocrystalline diamond tool with a single point is used, then machining precision can be maintained, but machining efficiency is low
Solution Approach 1:
The invention divides the tool structure into multiple cutting edges (at least two) arranged along the cutting direction, transforming a single-point tool into a multi-edge tool. This segmentation allows simultaneous engagement of multiple cutting edges with the workpiece, thereby increasing material removal rate and machining efficiency while maintaining the simplicity of the monocrystalline diamond material structure
2Productivity
If focused ion beam is used to form multiple cutting edges, then machining efficiency increases, but tool manufacturing cost increases
Solution Approach 1:
The invention replaces the focused ion beam process with pulsed laser grinding technology. The pulsed laser system uses optical energy to ablate and shape the monocrystalline diamond material, forming multiple cutting edges through controlled scanning motions. This substitution significantly reduces manufacturing cost while achieving the same multi-edge configuration that would otherwise require expensive ion beam processing
3Ease of manufacture
If pulsed laser grinding is used to machine flank face, then manufacturing cost is reduced, but forming multiple cutting edges requires precise scanning control
Solution Approach 1:
The invention employs periodic scanning paths where the laser beam scans back and forth across the flank face of the tool blank. By controlling the scanning speed, amplitude, and frequency, multiple cutting edges are formed through repeated passes. The periodic nature of the scanning motion simplifies the control algorithm while ensuring uniform distribution and consistent geometry of the cutting edges along the cutting direction
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 the efficient and cost-effective production of cutting tools with multiple cutting edges, improving machining efficiency while maintaining a low tool manufacturing cost.
Implementation Method 1
a process of scanning a cylindrical irradiation region including a focused spot of laser light that has been emitted to machine a flank face side of a workpiece
Data Source
AI summary
A controller performs a first process of scanning a cylindrical irradiation region including a focused spot of laser light emitted from a laser light emitter to machine a flank face side of a workpiece to manufacture a cutting tool having a plurality of cutting edges arranged in line. In the first process, the controller scans the cylindrical irradiation region along a scanning path that has periodicity and changes a machining depth to form the plurality of cutting edges. The controller further performs a second process of scanning the cylindrical irradiation region including the focused spot of the laser light emitted in a direction different from an irradiation direction of the laser light in the first process to machine a rake face side of the workpiece.