Through-Coolant Clamp Geometry for Stable Insert Cooling
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Solution Overview
Problem
Existing tool holders with through coolant clamps do not provide optimal coolant flow behavior due to operating conditions, which can affect the cooling efficiency of cutting inserts during machining operations.
Innovation Solution
A tool holder assembly with a through coolant clamp that includes a base portion with a fluid chamber, a nose portion with nozzles, and a transition outer surface for controlled coolant flow, ensuring a smooth transition between the fluid chamber and the nozzle inlet with a transition angle less than 60°.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If coolant flows directly from the fluid chamber to the nozzle inlet, then the structure is simple, but the coolant flow is turbulent and cooling efficiency is reduced
Solution Approach 1:
The transition outer surface is formed with a curved geometry that creates a smooth transition between the fluid chamber and nozzle inlet. This curved surface eliminates sharp angles and abrupt changes in flow direction, reducing turbulence and improving coolant flow characteristics while maintaining effective cooling of the cutting insert.
Solution Approach 2:
The transition outer surface modifies the flow parameters by creating a gradual pressure and velocity transition zone. The specific geometric parameters of the transition surface (curvature radius, transition angle less than 60°) are optimized to control coolant flow behavior, reducing turbulence intensity while maintaining sufficient cooling flow rate to the insert.
2Reliability
If the transition angle between fluid chamber and nozzle inlet is large, then the manufacturing is easier, but the coolant flow turbulence increases and cooling performance decreases
Solution Approach 1:
The transition outer surface employs a curved geometric profile with a transition angle less than 60° relative to the nozzle coolant channel axis. This curved transition geometry optimizes coolant flow by eliminating abrupt directional changes, reducing turbulence, and improving cooling performance while remaining manufacturable through standard machining or molding processes.
3Reliability
If coolant flow rate is increased to improve cooling, then the cooling efficiency improves, but the flow turbulence increases and flow control becomes difficult
Solution Approach 1:
The curved transition outer surface creates a streamlined flow path that maintains laminar or controlled turbulent flow even at higher coolant flow rates. The gradual curvature allows increased flow volume to pass through the clamp without proportionally increasing turbulence intensity, enabling better flow control and sustained cooling efficiency.
Solution Approach 2:
The transition surface geometry parameters are optimized to maintain favorable flow characteristics across a range of coolant flow rates. The specific curvature and transition angle design allow the system to handle variable flow rates while maintaining acceptable turbulence levels, providing operational flexibility and consistent cooling performance.
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 tool holder assembly achieves controlled and efficient coolant flow to the cutting insert, reducing turbulence and enhancing cooling performance, thereby improving machining efficiency and insert longevity.
Implementation Method 1
The transition outer surface forms a smooth transition between the coolant reservoir chamber and the nozzle inlet such that a transition angle measured in a plane perpendicular to the longitudinal axis of the through coolant clamp between at least a portion of the transition surface and the nozzle coolant channel axis is less than 60°
Data Source
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AI summary
A tool holder for cooling a cutting insert is disclosed. The tool holder may include a tool holder body, a cutting insert mounted on the tool holder body, and a through coolant clamp mounted to the tool holder body that secures the cutting insert to the tool holder body and provides coolant fluid to the cutting insert. The through coolant clamp may include a base portion with a fluid chamber extending radially outward from a clamp screw hole. A nose portion extends radially outward from the base portion, and at least one nozzle is provided within the nose portion extending along a nozzle axis. The nozzle includes a nozzle inlet and a nozzle outlet with a nozzle surface therebetween. The through coolant clamp may further include a transition outer surface in fluid communication with the fluid chamber and the nozzle inlet. The transition outer surface forms a smooth transition between the fluid chamber and the coolant channel inlet that provides controlled flow of the coolant through the coolant clamp.