Rotary Cutting Blade Material for Replaceable Shank Attachment
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Solution Overview
Problem
The existing rotary cutting tools require replacement of the entire superhard shank when the cutting blade wears out, leading to unnecessary costs due to the non-removable attachment, and the attaching means for brazing in existing constructions are not optimal for efficient attachment and brazing processes.
Innovation Solution
A rotary cutting blade material with an attaching structure forming portion made of a hard material, such as tungsten or tungsten carbide, that allows for mechanical fastening or brazing, providing improved attachability and vibration reduction, and a method for manufacturing this material involving sintering with specific properties to enhance joining and processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the cutting blade is non-removably attached to the superhard shank, then the strength and reliability of the attachment is improved, but the cost increases due to unnecessary replacement of the entire shank when the cutting blade wears out
Solution Approach 1:
The cutting blade is designed as a separate, removable component from the superhard shank through thread groove attachment. This segmentation allows the cutting blade to be replaced independently when worn, while the valuable superhard shank can be reused, thus resolving the contradiction between reliable attachment and material waste.
2Loss of substance
If the cutting blade is removably attached to the superhard shank, then the cost is reduced by reusing the shank, but the attachability and vibration resistance deteriorate
Solution Approach 1:
A thread groove attachment mechanism serves as an intermediary between the cutting blade and superhard shank. This intermediary provides a secure, vibration-resistant connection while maintaining removability, thus resolving the contradiction between cost reduction through shank reuse and maintaining attachment reliability.
3Ease of manufacture
If conventional attaching means are used for brazing, then the attachment process is simple, but the efficiency of attachment and brazing processes deteriorates
Solution Approach 1:
The attachment mechanism is segmented into a thread groove portion formed in the superhard shank and a corresponding threaded portion on the cutting blade. This segmentation enables efficient, standardized attachment and brazing processes while maintaining simplicity, resolving the contradiction between ease of manufacture and attachment efficiency.
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 solution enables the efficient replacement of only the cutting blade while maintaining the superhard shank, reducing costs and improving the service life by providing excellent attachability and vibration reduction, and ensuring a strong joining property during sintering.
Implementation Method 1
a rotary cutting blade material according to another aspect of the present disclosure is a hard material including a hard component and at least one element selected from an iron group element, and having a Young's modulus of not more than 350 GPa at a temperature of 25°C
Data Source
Figure 1A~1B
Figure 2A~2C
Figure 3
AI summary
A rotary cutting blade material has an attaching structure forming portion that is to serve as an attaching portion to the shank, a cutting structure forming portion that is to serve as a cutting blade, and a joint portion. The cutting structure forming portion has a core portion and a surface portion provided on the attaching structure forming portion with the joint portion being interposed, and the surface portion covers at least a part of a surface of the core portion. The attaching structure forming portion includes a hard material including a hard component and one or two or more types of iron group elements, and the hard material has a Young's modulus of not more than 350 GPa. The core portion includes a cemented carbide material, and the surface portion includes PCD or CBN. The hard component is at least one selected from the group consisting of W (tungsten), WC (tungsten carbide), TiC (titanium carbide), TiCN (titanium carbonitride), Al2O3 (alumina), and a combination of at least one of CBN (cubic boron nitride) and diamond and at least one of W and WC.