Sintered Circular Saw Tips With Built-In Rake and Flank Geometry
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Solution Overview
Problem
The complex shape of cutting edge tips in metal cutting circular saws requires multiple grinding processes, leading to high labor and cost expenses in achieving the desired cutting performance.
Innovation Solution
A method using upper and lower punches and a mortar die to form and sinter metal tips with predetermined angles and shapes, eliminating the need for extensive grinding by shaping the tip-forming metal material into a substantially rectangular parallelepiped shape with specific clearance and rake angles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple grinding processes are used to achieve complex cutting edge tip shapes, then cutting performance is improved, but manufacturing cost and labor time increase
Solution Approach 1:
The invention applies preliminary action by pre-forming the cutting edge tip shape during the sintering process itself, rather than forming it afterward through multiple grinding operations. The mold cavity is designed with the precise final shape including rake face, flank, clearance angle, and chip groove, so the tip is formed correctly from the beginning, eliminating the need for subsequent grinding processes.
Solution Approach 2:
The invention extracts the shaping function from the grinding process and integrates it into the sintering process. By incorporating the shape-forming capability directly into the mold cavity design, the complex multi-step grinding operation is removed entirely, leaving only the essential sintering and forming steps.
2Reliability
If multiple grinding operations are performed to create fine designs on rake face and flank, then cutting performance improves, but production time increases
Solution Approach 1:
The invention performs preliminary action by creating all fine design features (rake face geometry, flank geometry, clearance angles, chip dividing grooves) during the initial sintering process. The mold cavity is precisely engineered to produce the final complex shape in one operation, so no time-consuming subsequent grinding or machining operations are required, dramatically improving production efficiency while maintaining cutting performance.
3Manufacturing precision
If conventional grinding methods are used to form tip shapes, then precise angles are achieved, but manufacturing cost increases
Solution Approach 1:
The invention extracts the angle-forming function from the grinding process and incorporates it into the mold cavity design. The precise clearance angles and rake angles are built into the mold geometry itself, allowing these critical angular features to be formed during sintering without requiring expensive precision grinding operations, thereby reducing manufacturing cost while maintaining precision.
Solution Approach 2:
The invention merges the shaping function with the sintering process. Instead of separating forming and sintering into distinct operations (as in conventional grinding methods), the mold cavity performs both functions simultaneously - the cavity shape defines the final tip geometry including all angles and surfaces, and the sintering process consolidates the material to achieve the final dense form with precise geometry in one integrated 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 method simplifies and cost-reduces the manufacturing process by forming tips with precise angles through uniaxial forming and sintering, eliminating the need for conventional grinding and enabling efficient production of multiple tips simultaneously.
Implementation Method 1
sintering the tip formed product
Data Source
AI summary
The method for manufacturing a substantially rectangular parallelepiped tip 1 includes using an upper punch 25 for pressing a sand-like tip-forming metal material SM from above, a lower punch 26 for pressing the tip-forming metal material SM from below, and a mortar die 21 into which the tip-forming metal material SM is injected, making a lower surface 25a of the upper punch 25 into a forming surface of a rake face 2 side portion of the tip 1, making an upper surface 26a of the lower punch 26 into a forming surface of an opposite side surface 11 portion of the rake face 2 of the tip 1, and making one side inner surface 24a of the cavity 24 of the mortar die 21 into a forming surface of a flank 5 portion of the tip 1.