Replaceable Reamer Head Structure for Lower Tooling Cost
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Solution Overview
Problem
Existing reamer designs require the replacement of the superhard shank along with the cutting head, even when the shank is not worn out, leading to unnecessary costs due to the non-removable attachment of the cutting head to the superhard shank.
Innovation Solution
A reamer design featuring an attaching portion made of a hard material with specific properties, including tungsten, titanium carbide, or polycrystalline diamond, that allows for mechanical fastening or brazing, enabling the cutting head to be removably attached, thus allowing only the cutting head to be replaced when worn out, while maintaining the shank's service life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the cutting head is attached to the superhard shank in a non-removable manner, then the joining strength is improved, but the replacement cost increases when the cutting blade is worn out
Solution Approach 1:
The cutting head is divided into a cutting portion and an attaching portion made of different materials. The attaching portion is designed to be removable and is made of a material with lower hardness than the cutting portion, allowing selective replacement of only the cutting portion when worn, while retaining the attaching portion on the shank.
Solution Approach 2:
The hardness parameter of the attaching portion is deliberately reduced compared to the cutting portion. The attaching portion has a hardness of 1500 to 2500 HV, while the cutting portion has a hardness of 2500 to 4000 HV, enabling the attaching portion to be more easily replaced or reattached than the cutting portion.
2Productivity
If the cutting head is made with a hard material for high cutting performance, then the cutting ability is improved, but the ease of manufacture for attaching mechanisms deteriorates
Solution Approach 1:
Different parts of the cutting tool have different material properties optimized for their specific functions. The cutting portion uses extremely hard material for cutting performance, while the attaching portion uses a slightly softer material that is easier to machine and form with attaching mechanisms like thread grooves or brazing structures.
3Strength
If the attaching portion is made of the same hard material as the cutting portion, then the overall strength is improved, but the vibration reduction performance deteriorates
Solution Approach 1:
The cutting tool uses a composite structure with two different materials: an extremely hard cutting portion for cutting performance and a slightly softer attaching portion for vibration absorption. This composite construction allows the harder cutting portion to maintain strength while the softer attaching portion dampens vibrations during operation.
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 the cost of replacement by allowing only the cutting head to be replaced when worn, while providing improved vibration reduction and joining properties during sintering, enhancing the service life and performance of the cutting tool.
Implementation Method 1
improving vibration reduction and joining properties during sintering
Implementation Method 2
attaching means such as a thread groove for brazing the above-described construction and the tool carrier
Data Source
Figure 1A~1B
Figure 2A~2C
Figure 3
AI summary
A cutting tool according to one aspect of the present disclosure includes an attaching portion, a cutting portion having a core portion and a surface portion, and a joint portion. The attaching portion includes a hard component and a hard material. The hard component is at least one selected from the group consisting of TiC, TiCN, W, WC, Al2O3, and a combination of at least one of CBN and diamond and at least one of W and WC. The hard material includes one or two or more types of iron group elements, and has a Young's modulus of not more than 350 GPa. The core portion includes a cemented carbide material. The surface portion includes PCD or CBN. The cutting portion has a chamfer portion. The surface portion includes a groove, a flank face, and a cutting edge. The cutting edge extends toward the attaching portion. The flank face is formed of a chamfer flank face and an outer circumferential flank face. Inclination of the chamfer flank face with respect to a central axis is greater than inclination of the outer circumferential flank face with respect to the central axis.