Segmented Cutting Insert Structure to Minimize Brazing Gaps
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Solution Overview
Problem
The existing cutting tools face issues with gaps forming between hard sintered material pieces due to surface tension during brazing, leading to inefficiencies and increased material usage.
Innovation Solution
A cutting insert design featuring a substrate with a projection and a cutting-edge insert divided into pieces, where the pieces are brazed to surround the projection with displaced centers of gravity, reducing material usage and suppressing gap formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple hard sintered material pieces are joined to the core using conventional brazing, then the cutting tool can be assembled, but gaps form between the pieces due to surface tension during brazing
Solution Approach 1:
The cutting insert is divided into multiple divided pieces (first, second, third, and fourth divided pieces) that are arranged around the projection. Each piece has protrusions that interlock with adjacent pieces, creating a segmented structure that prevents gap formation while maintaining manufacturing precision.
Solution Approach 2:
The centers of gravity of the divided pieces are intentionally displaced from the vertices of the inscribed polygon. This asymmetric positioning, combined with the protrusion design, creates mechanical interlocking that counteracts surface tension forces during brazing, preventing gap formation and maintaining precise positioning.
2Loss of substance
If conventional cutting insert designs are used, then manufacturing is straightforward, but material usage is excessive and cutting edge utilization is reduced
Solution Approach 1:
The cutting insert is segmented into multiple divided pieces arranged around a central projection. This segmentation allows for optimized material distribution, reducing overall material consumption while maintaining structural integrity and maximizing the utilization of cutting edges across all pieces.
Solution Approach 2:
The design transitions from a conventional single-piece or simple multi-piece structure to a three-dimensional arrangement where pieces are positioned around a central projection with displaced centers of gravity. This spatial optimization reduces material waste and enhances cutting edge availability.
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 design effectively minimizes gaps between divided pieces, reduces material consumption, and enhances the use of cutting edges, thereby improving efficiency and lowering production costs.
Implementation Method 1
The cutting-edge insert is brazed to the top surface and the side surface so as to annularly surround the projection
Data Source
AI summary
A cutting insert includes a substrate and a cutting-edge insert. The substrate has, in a thickness direction of the substrate, a bottom surface, and a top surface opposite to the bottom surface. The top surface has a polygonal shape composed of a plurality of sides in a plan view as seen along the thickness direction. The top surface is provided with a projection projecting to a side opposite to the bottom surface along the thickness direction. The projection has a through-hole passing through the substrate along the thickness direction. The projection has a side surface contiguous to the top surface. The side surface is composed of a curved line protruding to a side opposite to the through-hole in the plan view as seen along the thickness direction.