PCD Milling Cutter With Concave Tips For Lens Processing
Solution Overview
Problem
Conventional PCD milling cutters for lens processing have high manufacturing costs due to wide installation surfaces and potential interference between the cutting blade and the workpiece, limiting their economic feasibility and productivity.
Innovation Solution
A PCD milling cutter design featuring a concave-shaped end portion for the PCD tip with a narrow installation surface and inclined, outward-protruding cutting blades, along with varying particle sizes and arrangements for enhanced abrasion resistance and durability, reducing material costs and interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the installation surface of the PCD tip is made wide to ensure stable welding and structural integrity, then the welding strength and reliability are improved, but the material cost increases due to excessive material usage
Solution Approach 1:
The PCD tip is designed with non-uniform cross-section where the installation surface width varies along the axial direction. The wider portion is located at the installation surface to ensure adequate welding area and strength, while the narrower portion reduces material usage. This local variation in geometry optimizes both welding strength and material efficiency.
2Ease of manufacture
If the cutting blade is designed with horizontal surface to simplify manufacturing, then the manufacturing process is easier, but the cutting blade interferes with the workpiece during operation
Solution Approach 1:
The cutting blade is designed with an asymmetric inclined surface instead of a horizontal surface. The inclination angle is optimized to prevent the cutting blade from interfering with the workpiece during rotation while maintaining effective cutting performance. This asymmetric geometry eliminates the harmful interference effect.
3Ease of manufacture
If the PCD tip uses uniform particle size for consistent material properties, then the manufacturing process is simplified, but the abrasion resistance and durability are reduced under high-temperature conditions
Solution Approach 1:
The PCD tip incorporates a composite structure with particles of different sizes distributed in specific regions. Larger particles are positioned in areas experiencing higher stress and temperature to enhance abrasion resistance, while smaller particles fill gaps and provide structural continuity. This localized particle size variation optimizes both durability and manufacturing feasibility.
Data Source
AI summary
Disclosed is a PCD milling cutter for lens processing. The PCD milling cutter includes a shaft having one axial end portion rotatably coupled with a driving unit of a milling unit for lens processing, a rotary head coupled with the axial end portion of the shaft and having a plurality of installation protrusions which protrude outward along a circumference thereof about a rotation center and have outer circumferential surfaces rounded in an axial direction of the shaft, and a plurality of PCD tips coupled with installation surfaces of the installation protrusions positioned in a rotation direction, provided at outer end portions thereof with rounded cutting blades sharply processed in the axial direction of the shaft, and provided in inner end portions thereof, which are opposite to the cutting blades, with cutting grooves formed in a concave shape to increase a welding force.