Cutting Insert Internal Coolant Passages Laser Ablation

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Solution Overview

Problem

In chipforming and material removal operations, excessive heat at the cutting edge-chip interface reduces tool life, leads to premature breakage and wear, and causes chip sticking, resulting in inefficient operations and increased costs.

Innovation Solution

Creating coolant holes using a laser beam to directly deliver coolant to the cutting edge-chip interface, allowing for precise and efficient coolant delivery and improved thermal management.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If conventional coolant delivery methods are used, then coolant is delivered to the cutting zone, but coolant delivery is insufficient at the cutting edge-chip interface resulting in excessive heat

Engineering Contradiction:

Improveheat at cutting edge-chip interfaceVSAvoidtool life

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The coolant delivery system is segmented into multiple internal passages within the insert body, allowing coolant to be delivered to multiple locations including the cutting edge-chip interface. This segmentation enables targeted cooling where heat generation is most critical.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The insert body acts as an intermediary structure with integrated internal coolant passages that transport coolant from the coolant source to the cutting edge-chip interface. This intermediary structure enables precise coolant delivery directly at the heat generation zone.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of manufacture

If higher operating temperatures are tolerated, then manufacturing complexity is reduced, but tool life is significantly reduced due to premature breakage and wear

Engineering Contradiction:

Improvemanufacturing complexityVSAvoiduseful tool life

Core Design Contradiction:

Ease of manufactureVSDuration of action of moving object

Solution Approach 1:

Coolant is delivered to the cutting edge-chip interface before excessive heat can accumulate and damage the tool. The internal passages are designed to provide preliminary cooling action that prevents heat buildup, thereby extending tool life without requiring complex manufacturing processes.

Inventive Principle:

Principle #10Preliminary action

3Temperature

If more coolant is used to cool the cutting zone, then heat removal is improved, but coolant consumption and environmental impact increase

Engineering Contradiction:

Improvecooling effectivenessVSAvoidcoolant consumption

Core Design Contradiction:

TemperatureVSLoss of substance

Solution Approach 1:

Coolant is delivered locally and directly to the cutting edge-chip interface where heat generation occurs. The internal passages concentrate coolant flow at the specific location needing cooling, improving cooling effectiveness while minimizing overall coolant consumption.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The insert structure itself serves as the coolant delivery system through its internal passages. This self-service design eliminates the need for external complex delivery mechanisms and reduces coolant consumption by delivering coolant only where needed within the insert.

Inventive Principle:

Principle #25Self-service

4Productivity

If chip evacuation is improved through better coolant flow, then re-cutting is minimized, but manufacturing complexity of the insert increases

Engineering Contradiction:

Improvechip evacuation efficiencyVSAvoidinsert structure complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The internal coolant passages serve multiple functions: they cool the cutting edge-chip interface, facilitate chip evacuation from the cutting zone, and reduce chip sticking. This multi-functionality improves productivity while minimizing the need for additional separate components that would increase complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 solution enhances lubrication, reduces chip sticking, and improves chip evacuation, extending tool life while minimizing coolant usage and environmental impact.

Implementation Method 1

Coolant holes are formed by a laser beam so that coolant can be delivered directly to the cutting edge-chip interface

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Implementation Method 2

enhanced delivery of coolant adjacent the interface between the cutting edge of the cutting insert and the workpiece (i.e., the cutting edge-chip interface) to diminish excessive heat at the cutting edge-chip interface

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS9895755B2Cutting insert with internal coolant passages and method of making same

Publication Date: 2018.02.20 KENNAMETAL INC

AI summary

A cutting insert (100, 100′) includes a body (102) having a top face (104), a bottom face (106) opposite the top face (104), and at least one flank face (108, 110, 112, 114). A coolant inlet aperture (126), a coolant outlet aperture (132, 134), and an internal coolant passage (128, 130) in fluid communication with the coolant inlet aperture (126) and the coolant outlet aperture (132, 134) are formed using electro-magnetic radiation. The coolant inlet aperture (126) can be formed in the top face (104), the bottom face (106) and/or the flank face (108, 110, 112, 114), and the coolant outlet aperture (132, 134) can be formed in any different face (104, 106, 108, 110, 112, 114). A method of forming the internal coolant passages (128, 130) is described.