Closed Chip Removal Channels in Rotary Machining Tools
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Solution Overview
Problem
Conventional machining tools, such as solid drilling tools, suffer from reduced stability and manufacturing quality due to open chip spaces, which allow chips to damage the hole wall and remain in recesses, and cannot effectively produce closed or twisted chip spaces.
Innovation Solution
The machining tool features an annularly radially outwardly closed chip removal channel with a one-piece outer chip space wall, formed through additive manufacturing, allowing for variable cross-sectional geometry and optimized chip removal, preventing chips from re-entering the hole and enhancing tool stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If open chip spaces are used in conventional machining tools, then chip removal is simple, but tool stability is reduced and chips damage the hole wall
Solution Approach 1:
The chip removal channel is segmented into multiple sections along its length, with each section having a different geometric configuration (circular, oval, rectangular, triangular cross-sections). This segmentation allows the channel to maintain structural integrity while efficiently removing chips through varied geometries optimized for different chip types and removal directions.
Solution Approach 2:
Multiple chip removal channels are nested within the tool body, with channels of different sizes and geometries arranged concentrically or in nested patterns. This nesting approach maximizes chip removal efficiency while maintaining tool stability by distributing material removal across multiple embedded channels rather than large open spaces.
2Ease of operation
If radially outwardly open chip spaces are used, then chip removal is straightforward, but manufacturing quality deteriorates due to chip damage to hole wall
Solution Approach 1:
Instead of opening chip spaces radially outwardly toward the hole wall, the chip removal channels are configured to exit through the tool periphery or bottom, directing chips away from the hole wall. This inverted approach maintains straightforward chip removal operations while preventing chip-induced damage to the manufactured hole surface.
Solution Approach 2:
The chip removal channels act as intermediary pathways that capture and transport chips away from the critical hole wall region. By providing dedicated intermediate channels for chip evacuation, the system separates the chip removal function from the hole formation process, preventing direct interaction between chips and the hole wall.
3Stability of the object's composition
If closed chip spaces are produced by milling, then tool stability increases, but tool length is limited to very short dimensions
Solution Approach 1:
The chip removal channels extend in multiple spatial dimensions within the tool body, including axial, radial, and tangential directions. By utilizing three-dimensional channel configurations rather than simple two-dimensional millable pockets, the design achieves closed stable structures that can accommodate long tool lengths while maintaining effective chip removal pathways.
Solution Approach 2:
The chip removal channels incorporate curved and spiral configurations rather than straight linear paths. These curved geometries distribute stress more evenly throughout the tool structure, enhancing stability for long tools while providing efficient chip removal through spiral or curved pathways that accommodate extended tool lengths.
4Productivity
If twisted chip spaces are produced by drilling, then chip removal is improved, but twisting of chip spaces cannot be effectively achieved
Solution Approach 1:
The chip removal channels incorporate dynamic geometric variations along their length, including changes in cross-sectional shape, orientation, and twist angle. This dynamic configuration optimizes chip removal efficiency at different positions along the tool, with twisted sections providing enhanced chip evacuation while maintaining manufacturability through controlled geometric progression rather than complex arbitrary twisting.
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 design increases tool rigidity, prevents chip re-entry, and improves manufacturing quality by ensuring chips are efficiently removed, allowing for longer tool lengths and complex hole geometries while maintaining surface smoothness.
Implementation Method 1
the outer chip space wall is formed by a powder material by means of an additive manufacturing process, in particular by selective laser melting
Implementation Method 2
Owing to centrifugal force, the chips are flung against the hole wall
Implementation Method 3
the chip removal channel to extend along the main body, optionally with a variable pitch, in a coiled or twisted manner
Data Source
AI summary
A machining tool for use in machine tools for rotating cutting operations has a main body, which can be rotated about a center axis and which is elongate in the direction of the center axis, at least one cutting element fastened to the main body and at least one chip removal channel, which extends along the main body outside of the center axis and which is bounded inwardly by a core of the main body, through which core the center axis passes. The chip removal channel is outwardly closed at least over a longitudinal section by an outer chip space wall adjoining the core.