Hard Sintered Tool Base Structure for Crack-Resistant Interfaces
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Solution Overview
Problem
The existing cutting tools, such as end mills and drills, are prone to cracks or chips near the interface between the base material and the cylinder portion due to perpendicular and shearing loads during operation, especially when machining difficult materials like carbon fiber reinforced plastic, which reduces machining efficiency.
Innovation Solution
A base material for a hard sintered body with a pillar portion featuring protruding stripe portions and specific peripheral configurations that distribute loads evenly, reducing the likelihood of cracks or chips at the interface by absorbing circumferential loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the cutting tool operates under normal cutting conditions, then machining efficiency is maintained, but cracks or chips occur near the interface between the base material and the cylinder portion due to perpendicular and shearing loads
Solution Approach 1:
The base material's outer peripheral portion is segmented into multiple protruding stripe portions that extend in the axial direction. These segmented structures distribute the shear stress and perpendicular loads across multiple contact points with the cylinder portion, preventing stress concentration at any single interface location and thereby preventing cracks or chips while maintaining structural integrity for efficient machining.
Solution Approach 2:
The protruding stripe portions create localized contact regions between the base material and the cylinder portion. By concentrating the bonding interface at these specific localized areas rather than across the entire peripheral surface, the design enhances the local strength at the interface where loads are applied, while the overall structure remains optimized for machining efficiency.
2Reliability
If the feed amount is reduced to reduce the load on the cutting tool, then the occurrence of cracks or chips is reduced, but machining efficiency is lowered
Solution Approach 1:
The segmented protruding stripe portions allow the cutting tool to withstand higher loads without interface failure by distributing stress across multiple bonding points. This enables the use of higher feed amounts and more aggressive cutting parameters to maintain machining efficiency while the segmented structure prevents cracks or chips by preventing stress concentration.
3Adaptability or versatility
If the cutting tool is used for machining difficult-to-cut materials such as carbon fiber reinforced plastic, then the machining capability is improved, but the load on the cutting tool increases causing cracks or chips at the interface
Solution Approach 1:
The localized protruding stripe portions create reinforced bonding zones that can withstand the high loads generated when machining difficult-to-cut materials like carbon fiber reinforced plastic. These local quality enhancements at the interface provide the necessary strength to handle the increased loads while maintaining the overall adaptability of the cutting tool for various material types.
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 enhances the fracturing resistance and extends the tool life of cutting tools by preventing cracks and chips at the interface, ensuring stable operation under varying loads.
Implementation Method 1
The base material and the cylinder portion are sintered integrally to form the hard sintered body
Data Source
AI summary
A base material for a hard sintered body includes a pillar portion having a central axis and extending in the axial direction of the central axis. The pillar portion has a first outer peripheral portion, a second outer peripheral portion, and a protruding stripe portion. In the cross-sectional view, one side portion of the first outer peripheral portion extending in a circumferential direction or a radial direction is located inside the other side portion. In the cross-sectional view, one side portion of the second outer peripheral portion extending in the circumferential direction or the radial direction is located outside the other side portion in the radial direction. The protruding stripe portion is located in a connection portion between the other side portion of the first outer peripheral portion and one side portion of the second outer peripheral portion, and protrudes outward.