Coating processes – Direct application of electrical – magnetic – wave – or... – Electromagnetic or particulate radiation utilized
Reexamination Certificate
1999-04-07
2001-11-13
Padgett, Marianne (Department: 1762)
Coating processes
Direct application of electrical, magnetic, wave, or...
Electromagnetic or particulate radiation utilized
C427S597000, C219S121660, C219S121820
Reexamination Certificate
active
06316065
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a method of manufacturing a cutting tool having at least one cutting body, a base body of the cutting tool being moved during the manufacture of the cutting body, a substance containing particles of cutting material being deposited on a bearing surface of the moved base body, and the substance being melted on the bearing surface and united with the bearing surface while solidifying to form the cutting body; and to an apparatus for the manufacture of a cutting tool having at least one cut tiny body, comprising a drive which drives the base body in the direction of displacement; supply means depositing a substance containing the particles of cutting material on a bearing surface of the tool base body; and a heating device melting the substance on the bearing surface and uniting it with the bearing surface for the manufacture of the cutting body.
2. Background Art
For the manufacture of a cutting tool it has been known to make the cutting body of the tool from metal bonded diamond layers. This is put into practice for instance by powder metallurgy or by plating out metals on pre-deposited diamond particles. The cutting bodies thus fabricated are then united with a base body of a tool by soldering or laser beam welding. Drawbacks of these known methods reside in the complicated and costly manufacture of the cutting tool which is accompanied with correspondingly high labor costs.
A less expensive way of producing the cutting tool is put into practice by the aid of single-stage laser beam coating. In this manufacturing process, the layer containing cutting material or the cutting body, respectively, are produced in one single operation and united with the metallic base body of the tool. During this operation, the base body of the tool is moved horizontally, i.e. transversely to the direction of the force of gravity. A substance containing the cutting material, for instance diamond particles, is deposited on the surface of the moved tool base body that will bear the future cutting body. A heating device subjects the bearing surface to heat energy. This is where a molten bath is formed, to which the substance is fed and where it is melted. A drawback of this manufacturing process resides in the floating of the particles of cutting material in the molten bath against the force of gravity. As a result of the high specific density difference of the individual components of the substance, the particles of cutting material shift within the cutting body molten bath when the lifetime of this melt is too long during the manufacturing process. As a result, there is no uniform distribution of the particles of cutting material within the volume of the cutting body, which would be necessary for a continuous cutting quality to be obtained throughout the height of the cutting body. A concentration of cutting material results in the outer area of the cutting body that is turned away vertically from the bearing surface, while the portions of the cutting body that are turned towards the bearing surface contain virtually no cutting material. The floating of the cutting material and the irregular distribution thereof along the overall height of the cutting body can be partially suppressed in the case of cutting body geometries of up to approximately 2 mm of width and 3 mm of height by a reduction of the setting time; in the case of cutting body geometries of greater dimensions, the irregular distribution of the cutting material can, however, not be prevented by modification of parameters such as advance velocity of the base body of the tool or substance mass flow rate.
SUMMARY OF THE INVENTION
It is an object of the invention to ensure a uniform distribution of the particles of cutting material within the cutting body during the production of a cutting tool with a substance containing cutting material being deposited on the base body of the tool.
According to the invention, the individual sections of the bearing surface seen in the direction of displacement of the tool base body are moved in a direction opposite to that of the force of gravity of the particles of cutting material during the setting time of the substance deposited on the respective section. In theory, the bearing surface can be divided into any number of infinitesimally small sections along the direction of displacement of the tool base body. A certain quantity of the substance is deposited successively on each of these sections, where it is melted. According to the invention, such a section with the quantity of substance deposited thereon is moved in a direction opposite to that of the force of gravity at least in the period between the melting of the quantity of substance and the solidification of this quantity of melt, i.e. at least during the setting time. In other words, regardless of the course of the bearing surface, the substance is always deposited on a section of the bearing surface that is moved against the direction of the force of gravity, where it is worked as a component of the cutting body. Due to the direction of displacement mentioned above of the section of the bearing surface with a quantity of the substance deposited thereon, floating of the particles of cutting material always takes place in the preceding section already solidified. Therefore, these solidified sections of the cutting body constitute a natural barrier against further floating of the particles of cutting material subsequently deposited on the bearing surface, there being no need of any additional implementation.
This floating of the particles of cutting material leads to the desired uniform distribution of the particles of cutting material in the lengthwise direction of the cutting body that is being produced, since during the production of the cutting body, infinitesimally small sections of substance melt line up in the lengthwise direction of the cutting body, all having the same particle floating behavior. Along the overall height of the cutting body, the conventional floating of the particles of cutting material is entirely avoided due to the arrangement and displacement of the bearing surface during the production of the cutting body.
A cutting body is produced according to the invention, having a substantially uniform distribution of the cutting material throughout its volume. This cutting body of considerably improved action can be produced at a low cost by a conventional apparatus, since only a modified position of the moving base body of the tool relative to the conventional manufacturing apparatus is necessary for the production of the cutting body. This position is such that the substance containing the cutting material is deposited only on the section of the bearing surface that is moved against the direction of the force of gravity. The position of the components relative to each other, i.e. of the devices within the manufacturing apparatus, may remain entirely unchanged. Therefore, the regular distribution of the cutting material within the cutting body is possible without any additional requirements in terms of cost and material.
The invention ensures a uniform distribution of cutting material within any cutting material volumes. This is true for plane bearing surfaces as well as for bearing surfaces equipped with a surface relief or designed to be curved in cross-section, in particular in the way of a segment of a cylinder jacket. Only the guidance of the base body of the tool must be such that each section of the bearing surface is moved in a direction opposite to that of the force of gravity at least during the setting time of the deposited substance melt.
The cutting materials may for instance be CBN, diamond or SiC.
For especially good regular distribution of the particles of cutting material within the cutting body, each individual section of the bearing surface is disposed precisely parallel to the direction of the force of gravity at least during the setting time of the substance melt allocated to it and its direction of displacement is disposed like
BLE Bayerisches Laserzentrum gemeinnutzige Forschungsgesellschaf
Browdy and Neimark
Padgett Marianne
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