Additive Cutting Tool Cavities for Lower Carbide Use
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Solution Overview
Problem
Conventional metal cutting tools made by press and sinter or extrude and sinter technology are limited in design, often requiring more material than necessary, leading to inferior features and high costs due to the use of expensive cemented tungsten carbide, which compromises tool quality and performance.
Innovation Solution
The development of cutting tools with an enclosed interior cavity and lattice or honeycomb structure produced using additive manufacturing techniques like binder jetting or selective laser sintering, allowing for reduced material usage while maintaining mechanical strength and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional press and sinter or extrude and sinter technology is used to manufacture cutting tools, then the manufacturing process is well-established and reliable, but the design is limited and excessive material is used leading to increased cost
Solution Approach 1:
The patent changes the manufacturing process parameter from conventional press/sinter or extrude/sinter methods to additive manufacturing (binder jetting or selective laser sintering). This parameter change enables complex internal geometries and cavities that were previously impossible to manufacture, thereby reducing material usage while maintaining structural integrity and tool performance
Solution Approach 2:
The patent introduces internal cavities and lattice structures within the cutting tool body, moving from a solid 3D form to a hollow 3D form with internal complexity. This dimensional utilization allows material removal from the interior while maintaining external geometry, significantly reducing overall material consumption
2Ease of manufacture
If conventional press and sinter or extrude and sinter technology is used to manufacture cutting tools, then the manufacturing process is well-established, but the design flexibility is limited leading to inferior features
Solution Approach 1:
The patent transitions from conventional manufacturing parameters (pressing, extruding) to additive manufacturing parameters (binder jetting, selective laser sintering). This enables the creation of complex internal geometries, varying wall thicknesses, and integrated features that cannot be achieved with traditional methods, dramatically increasing design flexibility
Solution Approach 2:
The patent divides the cutting tool into functional zones with different material densities and structures - solid regions for cutting edges, lattice structures for support, and hollow cavities for weight reduction. This segmentation allows optimization of each region for its specific function while maintaining overall tool performance
3Strength
If more material is used in cutting tools, then the tool has sufficient strength and durability, but the cost increases due to expensive cemented tungsten carbide
Solution Approach 1:
The patent applies different material distributions to different regions of the cutting tool - dense material at cutting edges for strength, lattice structures in support regions for adequate strength with less material, and hollow cavities in non-critical areas for maximum material reduction. This local quality optimization maintains strength where needed while reducing overall material usage
Solution Approach 2:
The patent utilizes cemented tungsten carbide composite material with cobalt binder, optimizing the carbide-to-binder ratio in different regions. The additive manufacturing process allows variation in material composition and density throughout the tool, creating a composite structure that maintains strength while reducing total material quantity
4Ease of manufacture
If conventional manufacturing methods are used, then the production process is straightforward, but the manufacturing time is longer
Solution Approach 1:
The patent combines multiple manufacturing operations into a single additive manufacturing process. Features such as cooling channels, internal cavities, lattice structures, and external geometry are all created in one build process rather than requiring sequential machining, molding, and assembly operations, thereby reducing total manufacturing time
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 results in cutting tools with improved mechanical properties, reduced weight, decreased manufacturing time and costs, and increased design flexibility, enabling more accurate high-speed operations and higher quality finished parts.
Implementation Method 1
producing a green cutting tool having an internal cavity from a starting powder using a binder jetting process
Implementation Method 2
The green shape is then sintered to compact and fuse the powder together
Implementation Method 3
producing a tool having an internal cavity from a starting powder using a selective laser sintering process
Data Source
AI summary
A cutting tool made by an additive manufacturing process is disclosed. The cutting tool has an exterior surface and an enclosed interior cavity defined by one or more inwardly facing surfaces. The interior cavity may have internal supports such as a lattice or a honeycomb structure. The cutting tool may be an insert, drill or endmill with coolant holes.