Rotary Cutting Tool with PCD Inserts for FRC Machining
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Solution Overview
Problem
Machining of fibre reinforced composites (FRCs) faces challenges such as delamination, burring, and heat generation, leading to reduced dimensional accuracy and increased costs due to the need for multiple tools and passes, with existing cutting tools like diamond grit, carbide, and PCD tools having limitations in flexibility, durability, and cost-effectiveness.
Innovation Solution
A rotary cutting tool with solid PCD inserts is developed, allowing for complex geometries and a combination cutting tool that provides high precision and fine finishes in a single pass, reducing tooling costs and extending tool life by distributing cutting forces and maintaining structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If diamond grit tools are used for high stock removal, then machining speed and feed are improved, but surface finish quality deteriorates requiring additional deburring tools
Solution Approach 1:
The patent combines roughing and finishing capabilities into a single end mill tool by integrating PCD inserts with varying flute geometries. The tool features both aggressive cutting geometry for stock removal and refined cutting edges for surface finishing, eliminating the need for separate deburring tools while maintaining high machining speeds.
Solution Approach 2:
The end mill is designed to perform multiple functions including roughing, semi-finishing, and finishing operations in a single tool. The PCD inserts are configured to provide both high material removal rates and superior surface finish quality, making the tool universal for various machining stages.
2Adaptability or versatility
If carbide burr tools are used for flexibility, then tool geometry adaptability is improved, but tool life deteriorates due to abrasion from FRC materials
Solution Approach 1:
The tool combines carbide base material with PCD (polycrystalline diamond) inserts. The carbide provides toughness and flexibility for various geometries, while the PCD inserts provide extreme wear resistance against FRC materials, achieving both adaptability and extended tool life.
Solution Approach 2:
Different parts of the tool have different material properties optimized for their specific functions. The carbide body provides structural flexibility and geometry adaptability, while the PCD inserts at the cutting edges provide localized wear resistance where contact with FRC materials occurs.
3Reliability
If straight multi-flute end mills are used to distribute load, then delamination is reduced, but separate cutting and finishing passes are required extending process complexity
Solution Approach 1:
The tool merges roughing and finishing capabilities into a single multi-flute end mill. The flutes are designed with varying geometries where some flutes are optimized for aggressive cutting to reduce delamination, while other flutes provide refined finishing, allowing both operations in one pass.
Solution Approach 2:
The end mill features segmented flutes with different geometries and PCD insert configurations. Each flute segment is optimized for specific cutting functions, enabling the tool to perform multiple operations simultaneously while distributing load to prevent delamination.
4Manufacturing precision
If helical geometry is used for constant shear and vibration reduction, then cutting quality is improved, but tool manufacturing cost and complexity increase
Solution Approach 1:
The tool features helical flute geometry in specific regions where it provides cutting quality benefits, while other regions use simpler geometries to reduce manufacturing complexity. The PCD inserts are positioned to maximize the benefits of helical geometry where needed while minimizing overall tool complexity.
Data Source
AI summary
A rotary cutting tool (10) comprises a shank (12) formed of a first material of a first hardness. The shank (12) has a first end (12a), and a plurality of elements (14) are provided at the first end (12a) of the shank (12). The elements (14) are formed of a second material of a second hardness greater than that of the first hardness. The elements (14) provide a platform to be able to create a plurality of cutting edges or teeth (18, 20a). A method of forming such a rotary cutting tool is also provided.