PCD Cutting Insert Layout for Non-Metal Machining Tool Life
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Solution Overview
Problem
Existing machining tools for non-metallic materials face challenges in economical production and efficient use of cutting edge material, leading to increased blunting and material waste due to double chipping and complex manufacturing processes.
Innovation Solution
The tool design features a support body with recesses that allow cutting inserts to be inserted circumferentially or axially, with an enveloping contour that aligns the seating surface with the cutting edge, enabling complete utilization of cutting edges through regrinding and a soldered connection that maintains material integrity throughout the tool's life cycle, along with trough-shaped depressions for inductive soldering and chip clearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If cutting inserts are inserted radially beyond the peripheral surface to avoid double chipping, then chip clearance is improved, but manufacturing complexity increases due to extensive material removal
Solution Approach 1:
Instead of making the cutting insert protrude radially beyond the peripheral surface, the invention inverts the approach by setting the inner edge of the rake face exactly at the enveloping contour. The cutting insert is positioned such that its rake face is inclined inward, eliminating the need for complex radially protruding holder structures while maintaining effective chip clearance through the trough-shaped depression design.
2Productivity
If cutting edges are positioned to maximize material utilization, then productivity improves, but manufacturing precision requirements increase to ensure proper alignment
Solution Approach 1:
The invention incorporates preliminary alignment features in the recess design, including a support surface perpendicular to the axis of rotation and a stop surface parallel to the axis of rotation. These pre-configured surfaces guide the cutting insert into the correct position during insertion, ensuring that the inner edge of the rake face aligns precisely with the enveloping contour without requiring complex post-installation adjustments or high-precision machining operations.
3Ease of manufacture
If traditional machining processes are used to produce cutter holders, then manufacturing flexibility is maintained, but material removal and production time increase
Solution Approach 1:
The recesses with their support and stop surfaces are pre-formed in the support body through turning operations before the cutting inserts are installed. This preliminary preparation of precise mounting features eliminates the need for extensive material removal and complex machining operations on the cutter holders themselves, significantly reducing production time while maintaining manufacturing flexibility.
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 design reduces sharpening work, minimizes material waste, extends tool life by preventing double chipping, and allows for cost-effective production and operation by ensuring the cutting edges are used almost completely, while maintaining process reliability and avoiding overheating.
Implementation Method 1
at least one cutting plate consisting of a support plate with a layer of polycrystalline diamond bonded by material bonding is inserted
Implementation Method 2
Trough-shaped depressions for inductive soldering
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
Tool for machining non-metallic materials with a support body (2) driven about a rotary axis (3), a plurality of first recesses (6) provided in the support body (2) on its outer contour, into each of which at least one cutting insert (9) consisting of a carrier plate with a materially bonded layer of polycrystalline diamond is inserted and to which chip flutes (22) leading in a direction of rotation (D) are assigned, wherein the chip flutes (22) are bounded by a surrounding contour (4) defined by the rotational contour of the support body (2) when the support body (2) is rotated about the rotary axis (3), and each first recess (6) has at least one seating surface (7) and at least one stop surface (8) acting against the direction of rotation (D), characterized in that the seating surface (7) is aligned on the surrounding contour (4) such thatthat the inner edge (12) of a chip surface (11) of the cutting inserts (9) lies substantially on the envelope contour (4), preferably exactly flush with the envelope contour (4).