Multi-blade Carbide Drill with Segmented Chip Flute Rib
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Solution Overview
Problem
Conventional solid carbide drills fail to maintain positional precision and surface quality when drilling deep holes into high-strength composite materials with alternating layers of aluminum, fiber-reinforced plastic, and titanium, often leading to chip congestion and premature tool breakage.
Innovation Solution
The drill features a chip flute design with a wave-shaped cross-section rib dividing it into two sections, promoting early chip breakage and increased stability, combined with internal coolant/lubricant channels and a reduced core cross-section, allowing for efficient chip removal and extended tool life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If conventional solid carbide drills are used for deep-hole drilling into composite materials, then tool stability is maintained, but chip congestion occurs and tool life is reduced
Solution Approach 1:
The chip flute is divided into two sections by a chip flute rib: a first section forming the cutting rake and a second section forming the chip flute runout. This segmentation allows chips to be broken into smaller segments that can be efficiently evacuated from deep holes, preventing chip congestion while maintaining tool stability throughout the cutting process
Solution Approach 2:
The chip flute is designed with a specifically optimized curvature radius in the first section to promote early chip breaking. The curved geometry of the chip flute rib creates controlled chip deformation zones that force chips to break at optimal points, enabling continuous chip evacuation and preventing the harmful accumulation of long chips in deep-hole drilling operations
2Object-generated harmful factors
If the core cross-section of the drill is reduced to increase chip space, then chip removal is improved, but tool stability decreases
Solution Approach 1:
The chip flute rib segments the chip flute into functional zones: the first section with optimized curvature for chip breaking and the second section for chip runout. This segmentation allows the core cross-section to be minimized in the chip formation zone while maintaining adequate structural support through the rib configuration, achieving both improved chip removal and sustained tool stability
Solution Approach 2:
The drill geometry is optimized locally: the core cross-section is reduced specifically in the chip formation zone where chip evacuation is most critical, while the chip flute rib provides localized structural reinforcement. This local quality adjustment allows enhanced chip space without compromising overall tool stability during deep-hole drilling operations
3Productivity
If the curvature radius of the chip flute is optimized to promote chip breaking, then chip evacuation is improved, but manufacturing complexity increases
Solution Approach 1:
The chip flute geometry is segmented into two distinct sections with different functional requirements: the first section with optimized curvature radius for chip breaking and the second section for chip runout. This segmentation allows each section to be independently optimized for its specific function while maintaining manufacturability through standardized grinding wheel profiles, balancing chip evacuation efficiency with manufacturing complexity
Data Source
AI summary
The invention relates to a multi-blade solid carbide drill for cutting high-strength sandwich materials. The tool comprises a shaft section and an adjoining cutting part, into which a number of chip flutes that corresponds to the number of main blades is incorporated. In order to reinforce the curvature of the resulting chip, the chip flute of the drill comprises a chip flute rib in the region of the chip formation zone, said rib protruding from the chip flute surface and having a substantially wave-shaped cross-section (28), and said rib dividing the chip flute into two sections, a first chip flute section (30) forming the cutting rake and a second chip flute (32) forming the chip flute runout.