Multiphase Tool With Embedded Diamonds For Hard Material Machining
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Solution Overview
Problem
Existing machining tools face challenges in efficiently machining high-strength, hard, and ultra-hard materials due to high tool wear and limited service life, requiring improved materials and techniques for effective material removal.
Innovation Solution
A multiphase tool with a two-phase material composition, featuring a matrix material and embedded diamonds, is used with a micro- or nano-structured surface, optimized for oscillating relative movement and inclined plane operation, enhancing wear resistance and machining efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional tools are used to machine high-strength, hard, and ultra-hard materials, then the machining process can be performed, but tool wear is high and service life is limited
Solution Approach 1:
The patent applies composite materials by creating a tool surface with a multiphase structure consisting of a matrix material and embedded diamond particles. This composite structure combines the toughness of the matrix material with the extreme hardness of diamond, enabling the tool to machine ultra-hard materials like cubic boron nitride and diamond while significantly reducing tool wear and extending service life.
Solution Approach 2:
The patent implements local quality by creating a micro- or nano-structured surface where diamond particles are selectively embedded in the matrix material at the tool surface. This localized enhancement of hardness and wear resistance at the cutting interface allows the tool to effectively machine ultra-hard materials while the bulk tool material maintains its original properties.
2Productivity
If conventional tools are used for machining, then the tool structure can be simple, but machining speed and chip volume removal per unit time are limited
Solution Approach 1:
The patent applies parameter changes by modifying the physical and chemical parameters of the tool surface through the multiphase material composition. The embedded diamond particles fundamentally change the surface hardness and friction characteristics, enabling higher machining speeds and improved chip removal rates without requiring complex tool geometries or mechanisms.
3Strength
If tools with high hardness are used to machine hard materials, then material removal is effective, but the tool material must possess very high hardness, strength, and toughness which are difficult to develop
Solution Approach 1:
The patent resolves the difficulty of developing tool materials with simultaneously high hardness, strength, and toughness by using composite materials. The matrix material provides toughness and strength, while the embedded diamond particles provide extreme hardness. This composite approach avoids the need to develop single-phase materials with all three properties.
Solution Approach 2:
The patent applies local quality by concentrating the hardness requirement at the tool surface where diamond particles are embedded, while the bulk tool material can have lower hardness but adequate strength and toughness. This localized approach simplifies material selection and manufacturing compared to requiring uniform high hardness throughout the entire tool.
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 tool achieves reduced wear, increased service life, and higher machining speed, effectively handling materials with Knoop hardness above 1, particularly those like cubic boron nitride and diamond, with efficient chip removal and minimal tool loading.
Implementation Method 1
a multiphase material and a corresponding tool which is comprised of the multiphase material, or has at least been coated with the latter. In particular the multiphase material takes the form of a two-phase material, that is to say, a material with precisely two phases... the said two-phase material is a mechanical alloy... the two-phase material is comprised at least of a matrix material and diamonds embedded in the latter
Data Source
AI summary
A workpiece accommodation device for purposes of accommodating a workpiece and for use in a device for the machining of a workpiece with: a tool mounting for purposes of accommodating the tool, a workpiece accommodation device for purposes of accommodating the workpiece, characterized in that during the machining process at least one first oscillation component can be introduced in a Z-direction, and an, in particular simultaneous, second oscillation component can be introduced in an X- and/or Y-direction by means of oscillation components.