Stem-Connected Cutting Inserts for Low-Loss Thin Insert Manufacturing

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Solution Overview

Problem

The manufacturing of complex cutting inserts is costly and prone to high loss rates due to difficulties in handling and processing, especially with traditional pressing techniques, which are inefficient for producing thin inserts and require costly operations like grinding and fixturing one-by-one.

Innovation Solution

A set of cutting inserts is designed with a stem portion and branch portions, made partially or entirely by injection molding and/or additive manufacturing using tungsten carbide, allowing for easier handling and processing, with the stem functioning as a handle to keep multiple inserts together during manufacturing and enabling detachment as needed.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If traditional pressing techniques are used to manufacture cutting inserts one at a time, then each insert can be individually formed, but the manufacturing cost increases and product loss increases due to difficult handling and processing

Engineering Contradiction:

Improvemanufacturing costVSAvoidproduct loss

Core Design Contradiction:

Ease of manufactureVSLoss of substance

Solution Approach 1:

Multiple cutting inserts are merged into a single molded component with integrated stem and branch portions, allowing them to be manufactured simultaneously as one piece rather than individually, thereby reducing manufacturing cost and product loss

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The molded component is segmented into multiple detachable cutting inserts connected through a stem portion with branch portions, enabling individual separation and use of each insert while maintaining the benefits of batch manufacturing

Inventive Principle:

Principle #1Segmentation

2Ease of manufacture

If conventional pressing techniques are used for thin inserts, then inserts can be formed, but the process becomes particularly difficult and handling becomes problematic

Engineering Contradiction:

Improveforming difficultyVSAvoidhandling difficulty

Core Design Contradiction:

Ease of manufactureVSEase of operation

Solution Approach 1:

Multiple thin inserts are combined into a single molded component with a stem portion, making them easier to handle as one piece rather than dealing with multiple separate thin inserts that are difficult to manage

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The stem portion acts as an intermediary structure that connects multiple thin inserts through branch portions, facilitating easier handling and processing during manufacturing while allowing individual inserts to remain thin for their intended application

Inventive Principle:

Principle #24Intermediary (Mediator)

3Productivity

If cutting inserts are manufactured one-by-one with grinding and fixturing, then each insert can be precisely finished, but the process becomes costly and time-consuming

Engineering Contradiction:

Improveproduction efficiencyVSAvoidmanufacturing cost

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

Multiple cutting inserts are manufactured simultaneously as a single molded component, eliminating the need for separate grinding and fixturing operations for each insert, thereby significantly improving productivity and reducing manufacturing cost

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The cutting inserts are pre-formed with their final shapes and cutting edges through the injection molding process, eliminating the need for subsequent grinding and fixturing operations that would be required if manufactured individually

Inventive Principle:

Principle #10Preliminary action

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 approach reduces product loss and simplifies the manufacturing process, particularly for thin inserts, by allowing for the simultaneous production and handling of multiple inserts, and facilitates efficient machining of grooves using the cutting inserts.

Implementation Method 1

The set is entirely or partly made by injection molding and/or additive manufacturing

Methodology Applied

Scientific EffectInjection molding:

Implementation Method 2

selectively fusing the tungsten carbide powder material by scanning the layers generated by a three-dimensional modeling program on the surface of the powder bed using a laser

Methodology Applied

Scientific EffectLaser selective fusion: Selective Laser Sintering

Implementation Method 3

pressing a carbide powder in a mold to form a green insert, then sintering the green insert

Methodology Applied

Scientific EffectSintering: Sintering

Data Source

PatentUS11027337B2Set of cutting inserts and methods of making a set of cutting inserts

Publication Date: 2021.06.08 SECO TOOLS AB

AI summary

A set of cutting inserts includes a stem portion, a plurality of branch portions attached to and extending from the stem portion, and at least one cutting insert attached to each of the plurality of branch portions. The stem portion has a longitudinal axis extending between a top end of the stem portion and a bottom end of the stem portion and at least one of the top end of the stem portion is disposed along the longitudinal axis above uppermost portions of each cutting insert, and the bottom end of the stem portion is disposed along the longitudinal axis below lowermost portions of each cutting insert. Also, methods for manufacturing a set of cutting inserts are disclosed.