Sensorized Cutting Insert With Narrow Recess Wear Detection

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Solution Overview

Problem

Existing cutting inserts for metal machining lack reliable and durable sensor arrangements that can withstand the rigors of machining operations, leading to potential damage and inaccurate wear detection, which can result in inefficient operation and potential damage to workpieces.

Innovation Solution

A cutting insert design featuring a sensor arrangement with an electrically conductive lead placed within a narrow recess, protected by a resistant first layer, which reduces the risk of damage and interference, allowing for longer-lasting and more reliable wear detection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the sensor circuit is made stable by arranging the conductor in a recess with width of 0.1 to 5 millimeters, then the reliability of the sensor arrangement is improved, but the manufacturing precision required increases due to the need for precise recess formation and conductor placement

Engineering Contradiction:

Improvestability of sensor circuitVSAvoidprecision of recess and conductor positioning

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The conductor is nested within the recess formed in the base material, creating a protected embedded structure. This nesting approach provides mechanical stability and protection while maintaining electrical functionality, resolving the contradiction between reliability and manufacturing precision by integrating the conductor into the existing recess structure rather than requiring separate precise positioning steps

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

An insulating film is introduced as an intermediary layer between the conductor and the base material. This intermediary element provides electrical insulation and mechanical support, allowing the conductor to be positioned reliably in the recess without requiring extremely tight tolerances on the recess dimensions themselves, thus reducing the manufacturing precision requirement while maintaining sensor circuit stability

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of manufacture

If the conductor is placed closer to the surface for easier manufacturing, then the ease of manufacture is improved, but the sensor arrangement becomes more susceptible to damage and disconnection

Engineering Contradiction:

Improveease of conductor placementVSAvoiddurability of sensor arrangement

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The conductor is nested within the recess rather than placed on the surface, providing natural mechanical protection against damage and disconnection. The recess structure acts as a protective housing that shields the conductor while allowing standard manufacturing processes to be used, thus maintaining ease of manufacture while significantly improving reliability

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The recess structure provides beforehand cushioning and protection for the conductor against mechanical stresses, vibrations, and thermal expansion during machining operations. This pre-established protective structure prevents damage before it can occur, allowing the conductor to be manufactured using conventional techniques without requiring post-manufacturing protection measures

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Reliability

If the recess width is reduced to less than or equal to 80 micrometers for better sensor protection, then the reliability of the sensor arrangement is improved, but the device complexity increases due to the need for precise narrow recess formation

Engineering Contradiction:

Improveprotection of sensor arrangementVSAvoidcomplexity of recess formation process

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The recess width parameter is optimized to less than or equal to 80 micrometers at critical depths where the conductor is positioned. This parameter change provides sufficient protection for the sensor arrangement while remaining achievable with standard precision manufacturing techniques. The specific dimensional parameter resolves the contradiction by defining a threshold that balances protection requirements with manufacturing capability

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The recess is designed with varying width at different depths, being narrower (≤80 micrometers) at the depth where the conductor is positioned and potentially wider at the surface. This local quality variation provides maximum protection where needed while simplifying the overall manufacturing process, as the narrowest section only needs to be precise at the conductor location rather than throughout the entire recess length

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS20240033830A1Cutting insert with sensor arrangement and method for manufacturing a cutting insert

Publication Date: 2024.02.01 SANDVIK INTELLECTUAL PROPERTY AB

AI summary

A cutting insert for cutting, milling or drilling of metal includes a body having an elongate recess extending along at least a portion of the body, a first layer covering interior side walls of the recess, and a sensor arrangement. The body includes a substrate. The sensor arrangement includes sa lead extending along the recess. The lead includes electrically conductive material, which is arranged in the recess such that the first layer is located between the electrically conductive material and the substrate. For at least a depth below which at least a portion of the electrically conductive material is arranged in the recess, a width of the recess measured at that depth between portions of the first layer covering opposite interior side walls of the recess is less than or equal to 80 micrometers.