Wet Blasting Cutting Insert Coating Removal
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Solution Overview
Problem
Existing methods for surface-coated cutting inserts, such as brushing and dry blasting, often result in excessive removal of coating layers and surface roughness deterioration, particularly at the intersecting edge line region, and are inefficient for treating both sides of negative type cutting inserts.
Innovation Solution
A method involving wet blasting using a pair of rotary shafts to rotate the cutting insert while jetting an abrasive fluid from blasting guns, allowing for controlled rotational velocity and jetting pressure, and adjustable jetting angles to ensure uniform and efficient treatment without over-treating the intersecting edge line region.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If mechanical removal methods (brushing, polishing, dry blasting) are used to remove coating layers, then the coating layer can be removed, but excessive removal occurs and surface roughness deteriorates
Solution Approach 1:
The patent introduces water as an intermediary medium in wet blasting to moderate the impact energy of abrasive particles. The abrasive fluid (water mixed with abrasive particles) acts as a mediator between the blasting apparatus and the coating layer, reducing excessive impact forces that cause surface damage while maintaining effective coating removal capability.
Solution Approach 2:
The patent changes the physical state and properties of the blasting medium from dry abrasive particles to an abrasive fluid (liquid mixture). This parameter change in the blasting medium's density, viscosity, and energy distribution allows for controlled coating removal with reduced surface damage compared to dry mechanical methods.
2Productivity
If one-sided treatment methods are used for cutting inserts, then the treatment process is simple, but treatment efficiency is low for negative type inserts requiring both sides treatment
Solution Approach 1:
The patent combines multiple blasting nozzles and positioning mechanisms into a single integrated apparatus that can treat both sides of the cutting insert simultaneously or sequentially. The rotating table or dual-sided positioning system merges the treatment of opposite faces into one unified process, doubling productivity without proportionally increasing complexity.
Solution Approach 2:
The blasting apparatus is designed with multi-functionality to handle various cutting insert types and treat multiple surfaces. The apparatus can switch between treating single sides and both sides, accommodate different insert geometries, and perform both coating removal and surface smoothing functions, making it universally applicable and highly efficient.
3Manufacturing precision
If jetting direction is fixed in one direction, then the treatment process is simple, but the whole periphery of the cutting insert is not uniformly treated
Solution Approach 1:
The patent employs dynamic positioning of the blasting nozzle or workpiece, where the jetting direction changes during the treatment process. Rotating tables, articulated arms, or programmable nozzle positioning systems dynamically adjust the blasting angle and position to ensure uniform treatment across the entire periphery of the cutting insert, transforming a static single-direction process into a dynamic multi-angle process.
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
Prevents excessive removal of coating layers and surface roughness deterioration, enables uniform treatment of both sides of cutting inserts, and facilitates mass production with improved automation and surface quality.
Implementation Method 1
jetting an abrasive fluid to the surface of the surface-coated cutting insert while rotating the surface-coated cutting insert, thereby, conducting wet blasting
Data Source
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AI summary
This method for manufacturing a surface-coated cutting insert includes clamping and holding a surface-coated cutting insert with a pair of rotary shafts which are rotatable around an axis, and jetting an abrasive fluid to the surface of the surface-coated cutting insert using at least one blasting gun while rotating the surface-coated cutting insert, thereby, conducting wet blasting.