PCD Cutting Edge Brazing Structure for Faster Tool Manufacturing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing throw away tip manufacturing process is costly and time-consuming due to the need to grind both the ultra-high hardness sintered material and the backing plate to form the cutting edge, which shortens the tool's life and increases production costs.
Innovation Solution
A cutting tool with a polycrystalline diamond sintered material blade edge member fixed to a base metal using a brazing material, where the cutting edge is formed by laser processing the flank face without a grindstone, eliminating the need to process the backing plate and reducing manufacturing time and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If grinding is used to form the cutting edge on both the ultra-high hardness sintered material and the backing plate, then the cutting edge can be formed with high precision, but the manufacturing time increases and production cost increases
Solution Approach 1:
The invention extracts and removes the backing plate from the manufacturing process. By using a blade edge member whose entire thickness serves as the cutting portion without requiring a separate backing plate, the grinding process is simplified to only process the blade edge member itself, eliminating the time-consuming step of grinding both the sintered material and the backing plate while maintaining cutting edge precision
Solution Approach 2:
The invention segments the cutting tool structure into a base metal with a seat portion and a separate blade edge member made of ultra-high hardness sintered material. This segmentation allows the blade edge member to be independently manufactured and processed, enabling the cutting edge to be formed by grinding only the blade edge member without involving a separate backing plate, thus reducing manufacturing time while maintaining precision
2Manufacturing precision
If grinding is used to form the cutting edge on the backing plate, then the cutting edge can be formed, but the tool life is shortened due to reduced wear resistance
Solution Approach 1:
The invention extracts and eliminates the backing plate from the cutting structure. The blade edge member is designed so that its entire thickness contributes to the cutting function, removing the need for a separate backing plate that would have reduced wear resistance. This extends tool life while still enabling precise cutting edge formation through grinding of the blade edge member alone
Solution Approach 2:
The invention uses ultra-high hardness sintered material for the blade edge member, which is a composite material with superior wear resistance compared to traditional backing plate materials. This composite material structure allows the entire blade edge member to serve as the cutting portion, extending tool life while maintaining the ability to form a precise cutting edge through grinding
3Manufacturing precision
If traditional manufacturing process with backing plate is used, then the cutting edge can be formed, but the production cost increases
Solution Approach 1:
The invention extracts and removes the backing plate from the manufacturing process. By designing the blade edge member to serve as the complete cutting structure without requiring a separate backing plate, the manufacturing process is simplified, reducing material costs, processing costs, and production complexity while maintaining the ability to form a precise cutting edge through grinding of the blade edge member alone
Solution Approach 2:
The invention segments the cutting tool into a base metal and a blade edge member, where the blade edge member is independently manufactured from ultra-high hardness sintered material. This segmentation enables cost-effective manufacturing by allowing the blade edge member to be produced separately and then mounted on the base metal, eliminating the need for expensive backing plate materials and the complex process of grinding both components
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 cutting edge can be formed at a lower cost without shortening the tool's life, with improved wear resistance and lubricity, and the method prevents brazing material melting, ensuring a longer tool life and reduced production costs.
Implementation Method 1
a brazing material that fixes the blade edge member to the seat portion of the base metal
Implementation Method 2
forming the cutting edge by performing laser processing on the flank face of the sintered blade edge material with a laser beam applied along the flank face of the sintered blade edge material
Data Source
AI summary
A cutting tool includes: a base metal provided with a seat portion; a blade edge member that is a polycrystalline diamond sintered material containing polycrystalline diamond and a binder; and a brazing material that fixes the blade edge member to the seat portion of the base metal. The blade edge member has a thickness of greater than or equal to 0.3 mm. The brazing material is disposed between a blade edge bottom face of the blade edge member and a seat bottom face of the seat portion and is in contact with the blade edge bottom face and the seat bottom face. The flank face is located outside of the base metal with respect to the lateral face of the base metal.