Multi-Layer Cutting Tool Geometry for Coated Cut Edges
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Solution Overview
Problem
Existing methods for cutting multi-layered materials, such as plated steel sheets, often result in cut end surfaces that are not fully coated with the protective layer, leading to reduced corrosion resistance and increased labor and cost due to the need for after-machining repairs, and can also form burrs or reduce yield rates.
Innovation Solution
A cutting apparatus with first and second tools having inclined and protruding portions, where the inclined surface is 15° to 45° inclined and the protruding portion has a vertical wall surface, ensures the coating material is dragged into the cut end surface, preventing burr formation and maintaining corrosion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional cutting methods are used to cut multi-layered materials, then the cutting process is simple and fast, but the cut end surface is not fully coated with protective layer, leading to reduced corrosion resistance
Solution Approach 1:
The coating material is dragged into the cut end surface during the cutting process itself, rather than applying coating after cutting. This preliminary action ensures the protective layer is in place before the material is put into service, eliminating the need for separate after-machining repair steps while maintaining corrosion resistance.
Solution Approach 2:
The invention changes the geometric parameters of the cutting tools (blade angles, edge radii, clearance distances) to optimize the dragging of coating material into the cut end surface. By adjusting these parameters, the cutting process simultaneously achieves both cutting function and coating deposition function.
2Productivity
If conventional cutting methods are used, then the cutting process is simple, but after-machining repair is required which increases labor and cost
Solution Approach 1:
The invention merges the cutting function and coating deposition function into a single integrated process. The cutting tools are designed to simultaneously cut the material and drag coating material into the cut end surface, eliminating the need for separate after-machining repair operations and reducing total process steps.
Solution Approach 2:
The cutting process itself serves the dual purpose of cutting and coating application. The coating material is automatically dragged into the cut end surface by the cutting tools during the cutting operation, making the process self-sufficient without requiring additional repair operations.
3Manufacturing precision
If conventional cutting methods are used, then the cutting process is straightforward, but burrs and protrusions remain at the cut end surface
Solution Approach 1:
The invention optimizes the geometric parameters of the cutting tools, including blade angles (15°-45°), edge radii (0.03-0.30mm), and clearance distances, to prevent burr formation. These parameter changes enable the tools to cut cleanly while simultaneously dragging coating material into the cut end surface, achieving both precision and protective coating.
Data Source
AI summary
There is provided a cutting apparatus for cutting a multi-layered material sandwiched between a first tool and a second tool, including the first tool and the second tool are disposed such that blade portions of the first tool and the second tool face each other in a pressing direction, at least any one of the blade portions of the first tool and the second tool includes: an inclined portion including a tool inclined surface that is inclined with respect to the pressing direction; and a protruding portion including a vertical wall surface and a pressing surface and protruding from the inclined portion in the pressing direction, the vertical wall surface extending from the tool inclined surface along the pressing direction, the pressing surface being perpendicular to the vertical wall surface, and the inclined portion overlaps a tool facing the inclined portion as viewed in the pressing direction.