Laser-Etched PCBN Cutting Insert Chip Breaker for Heat Control

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Solution Overview

Problem

Cutting inserts with superhard materials like PCBN or PCD face limitations in chip breaker design and control, leading to high temperatures, reduced strength, and unpredictable wear due to the inability to form chip breakers during pressing, which restricts cutting speed and increases the risk of chip deformation and edge damage.

Innovation Solution

A cutting insert with a superhard sintered body featuring a smoothly curved chip breaker formed by laser etching, providing a concave profile that reduces friction and heat generation, allowing for improved chip formation and control, and enabling increased cutting speed or reduced superhard sintered body size for cost efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a chip breaker is formed by grinding in superhard materials (PCBN/PCD), then the cutting insert can be manufactured, but the design options are limited and manufacturing complexity increases

Engineering Contradiction:

Improvechip breaker formationVSAvoidmanufacturing process

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent replaces the mechanical grinding process with a laser-based forming process. The laser beam melts and vaporizes the superhard material to create the chip breaker geometry, eliminating the need for complex mechanical grinding operations and enabling greater design freedom.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the physical state and properties of the superhard material through laser heating, transforming it from a solid that requires mechanical removal to a material that can be selectively melted and vaporized. This parameter change enables new manufacturing capabilities.

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If the chip breaker has a conventional design, then manufacturing is simpler, but chip control is poor leading to high temperatures

Engineering Contradiction:

Improvechip breaker designVSAvoidmachining temperature

Core Design Contradiction:

Ease of manufactureVSTemperature

Solution Approach 1:

The patent implements a concave chip breaker profile with specific curvature radii (R1 for the chip breaker bottom, R2 for the transition). This curved geometry optimizes chip flow and control, reducing friction and heat generation during machining operations.

Inventive Principle:

Principle #14Spheroidality (Curvature)

3Productivity

If cutting speed is increased to improve productivity, then production efficiency increases, but temperatures rise causing braze joint softening and reduced strength

Engineering Contradiction:

Improvecutting speedVSAvoidbraze joint strength

Core Design Contradiction:

ProductivityVSStrength

Solution Approach 1:

The patent converts the potential harm of high temperatures into a benefit by designing a chip breaker geometry that actively manages heat generation. The concave profile with optimized radii promotes efficient chip evacuation and reduces friction, allowing high cutting speeds without compromising braze joint integrity.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

4Reliability

If a small superhard sintered body is brazed to cemented carbide to reduce cost, then manufacturing cost decreases, but the braze joint is vulnerable to softening at high temperatures

Engineering Contradiction:

Improvecutting edge strengthVSAvoidbraze joint temperature

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The patent uses a concave chip breaker profile with specifically optimized curvature radii to reduce friction between the chip and the cutting insert. This geometric optimization allows the braze joint to operate at higher temperatures without softening, enabling the use of cost-effective small superhard sintered bodies.

Inventive Principle:

Principle #14Spheroidality (Curvature)

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 smooth concave profile of the chip breaker enhances chip flow, reduces friction and heat, and maintains cutting edge stability, improving machining efficiency and reducing the risk of damage, particularly for inserts with brazed superhard bodies.

Implementation Method 1

wherein laser etching is used in the forming of the chip breaker

Methodology Applied

Scientific EffectLaser heating: Laser

Data Source

PatentEP3421160B1A cutting insert and a method of manufacturing a cutting insert

Publication Date: 2022.08.10 SECO TOOLS AB

Figure 1~3
Figure 4~6
Figure 7~9

AI summary

A cutting insert (1) for a cutting tool, having a cutting edge (7) of PCBN or PCD formed in a corner region of the cutting insert in a transition between a side surface (6) and a chamfer (4) formed in an upper side (2) of the cutting insert. A chip breaker (9) is formed in the chamfer inside of the cutting edge, extending between a lower chamfer portion (10) and an upper chamfer portion (11), wherein the chip breaker comprises a chip breaker bottom (12) connected to the lower chamfer portion and a chip breaker wall (13) extending from the upper chamfer portion to the chip breaker bottom. An upper transition (16) is formed between the upper chamfer portion and the chip breaker wall. As seen in a top view, the upper transition follows a smoothly curved path (14) comprising a convex middle portion (18). As seen in a section perpendicular to the cutting edge, the chip breaker wall and the chip breaker bottom together forms a smooth concave profile. The chip breaker is formed using laser etching.