Adjustable Fan Spray Nozzle for Cutting Insert Cooling
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Solution Overview
Problem
Existing coolant delivery systems for machining and metalworking operations fail to effectively impinge the entire length of the insert-chip interface, leading to excessive heat, reduced tool life, and increased re-cutting of chips, due to limitations in coolant duct sizing and directionality.
Innovation Solution
A coolant spray nozzle with an adjustable fan spray nipple that can be directed 360 degrees to impinge the insert-chip interface along its entire length, providing a fan-shaped coolant spray that covers the entire cutting edge, enhancing coolant delivery and reducing heat at the interface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If a coolant duct with a small drill bit is used to deliver coolant near the insert-chip interface, then coolant delivery pressure is improved, but manufacturing complexity and downtime increase due to difficult drilling and small bit breakage
Solution Approach 1:
The coolant delivery system uses an adjustable spray nozzle that can be positioned and angled to direct coolant precisely at the insert-chip interface. This dynamic adjustment capability eliminates the need for complex drilling operations to achieve optimal coolant delivery, while maintaining high coolant pressure through proper spray direction rather than relying solely on duct size
Solution Approach 2:
The invention changes the approach from modifying duct dimensions (small drill bits) to adjusting spray parameters (nozzle angle and position). By changing the delivery mechanism from fixed duct geometry to adjustable spray parameters, the system achieves high coolant pressure without the manufacturing complexities of small bit drilling
2Reliability
If a coolant spray nozzle is used to deliver coolant to the insert-chip interface, then coolant delivery effectiveness is improved, but the ability to cover the entire insert-chip interface length is limited by fixed nozzle direction
Solution Approach 1:
The spray nozzle is designed with adjustable angle and position capabilities, allowing it to adapt to different insert-chip interface configurations. This dynamic adjustability enables the single nozzle to cover the entire interface length by directing spray at multiple angles, eliminating the need for multiple fixed nozzles while maintaining effective coolant delivery
Solution Approach 2:
The adjustable spray nozzle serves multiple functions: it can deliver coolant to different positions along the insert-chip interface, adjust to various spray angles, and adapt to different cutting conditions. This multi-functionality allows a single nozzle design to provide comprehensive coverage of the entire interface length while maintaining effective coolant delivery
3Duration of action of stationary object
If excessive heat is not reduced at the insert-chip interface, then tool life is reduced due to chip welding and re-cutting, but adding complex coolant delivery systems increases device complexity
Solution Approach 1:
The adjustable spray nozzle provides dynamic coolant delivery that adapts to the specific cutting conditions and insert position. This targeted, adjustable approach delivers coolant precisely where needed to prevent chip welding and re-cutting, extending tool life without requiring complex multi-nozzle systems or elaborate delivery mechanisms
Solution Approach 2:
The invention applies coolant delivery with local quality by directing spray precisely at the insert-chip interface where heat generation occurs. The adjustable nozzle concentrates coolant delivery at the critical interface zone to prevent chip welding and re-cutting, extending tool life through targeted local cooling rather than diffuse system-wide cooling
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 adjustable coolant spray nozzle increases the useful life of cutting inserts by reducing chip welding and re-cutting, improving production efficiency and simplifying manufacturing by allowing flexibility in thread design and duct location.
Implementation Method 1
a coolant spray nozzle...facilitate enhanced delivery of coolant adjacent the interface between the cutting (or milling) insert and the workpiece (i.e., the insert-chip interface) to diminish excessive heat at the insert-chip interface
Implementation Method 2
under certain conditions enables faster cutting or machining of the work piece, by reducing friction and assisting in heat transfer from the work piece to the cutting tool at the insert-chip interface
Data Source
AI summary
A coolant spray nozzle for use in conjunction with a cutter with a coolant duct wherein the cutter retains a cutting insert with a cutting edge that engages a workpiece at an insert-chip interface having a length. The coolant spray nozzle includes a coolant spray nozzle body containing a bore and an adjustable fan spray nipple having a slot with a slot opening through which coolant discharges in a fan-shaped coolant spray so as to impinge the insert-chip interface along substantially the entire length of the insert-chip interface.