Segmented Cutting Disc With Offset Segments
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Solution Overview
Problem
Existing diamond cutting discs are limited in their ability to cut wider notches, as their cutting width is restricted to a few millimeters, making them unsuitable for cutting materials like fibrous plastics without coolant, which leads to clogging and inefficiency, and require expensive milling tools for wider cuts.
Innovation Solution
The cutting disc design features cutting segments offset from the central cutting plane, allowing for increased cutting width by bending or welding the segments to protrude beyond the plane, enabling wider cuts and improved cooling, thus allowing for efficient processing of previously inaccessible materials like fibrous plastics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If cutting segments are arranged in a single cutting plane, then the structure is simple and easy to manufacture, but the cutting width is limited to a few millimeters
Solution Approach 1:
The cutting segments are arranged in multiple cutting planes instead of a single plane, transitioning from a 2D arrangement to a 3D spatial configuration. This dimensional change allows the cutting width to extend beyond the limited single-plane constraint, enabling cuts several times wider than traditional discs while maintaining structural feasibility through controlled spatial distribution of segments.
Solution Approach 2:
The cutting disc is divided into multiple independent cutting segments distributed across different cutting planes. Each segment can be independently positioned and oriented, allowing the overall cutting width to be significantly increased by distributing segments radially and angularly across multiple planes, rather than confining them to a single narrow plane.
2Length of moving object
If cutting segments are arranged in multiple cutting planes, then the cutting width increases, but the risk of imbalance increases
Solution Approach 1:
The cutting segments are asymmetrically distributed across multiple cutting planes with varying radial and angular positions. This asymmetric arrangement allows optimization of the center of gravity position and moment distribution, enabling the disc to maintain balance stability while achieving significantly increased cutting width through multi-plane segment configuration.
Solution Approach 2:
The distribution of cutting segments across multiple planes creates counterbalancing effects where segments in different planes and angular positions compensate for each other's gravitational and centrifugal forces. This counterweight principle ensures that the increased cutting width from multi-plane arrangement does not compromise the rotational balance and stability of the disc.
3Productivity
If traditional cutting discs are used for fibrous plastics, then the disc becomes clogged, but using milling tools is expensive and complex
Solution Approach 1:
By arranging cutting segments in multiple cutting planes rather than a single plane, the invention creates additional spatial dimensions for chip evacuation and cooling airflow. This multi-plane configuration prevents material from accumulating and clogging the cutting zone, enabling efficient processing of fibrous plastics without the need for expensive milling tools or complex coolant systems.
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 enables cutting widths several times greater than traditional discs, facilitating the use of diamond cutting discs for wider notches and slots, reducing the need for milling tools, and preventing clogging, allowing for efficient processing of materials like fibrous plastics without coolant.
Implementation Method 1
As diamond cutting discs, they have a particularly long service life and are easy to cut. The long service life is primarily achieved through the use of industrial diamonds on the cutting edges of the cutting segments.
Implementation Method 2
The more or less large segmentation primarily contributes to the cooling of the tool.
Data Source
Figure 1~2d
Figure 3~4
Figure 5~6
AI summary
A segmented cutting disc, in particular a diamond cutting disc, having a disc body 1 and having cutting segments 2 distributed over the circumference of the disc body 1, wherein the disc body 1 defines a central cutting plane 4, and wherein a segment gap 3 remains in each case between two cutting segments 2, said segment gap having cutting segments 2 of which the cutting edges are arranged offset in relation to the central cutting plane 4.