Cutting Insert Clamping With Sealed Coolant Channels
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Solution Overview
Problem
Existing tool systems for machining difficult-to-cut materials like nickel-based alloys and titanium alloys face challenges in maintaining process optimization while ensuring quality and reducing manufacturing costs, particularly in effectively cooling the processing area to extend cutting tool life and increase machining parameters.
Innovation Solution
A tool system with a tool holder and clamping element that includes fluid channels for cooling, a sealing element for pressure-tight fluid channel connections, and a clamping mechanism with angled contact surfaces to ensure secure positioning and efficient coolant delivery to the shear zone, allowing for higher feed rates and cutting depths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a seal is arranged between the clamping element and the tool holder to ensure fluid-tight connection, then the cooling function is maintained, but the seal must be replaced together with the cutting insert which increases maintenance cost and downtime
Solution Approach 1:
The sealing function is segmented from the cutting insert and assigned to the clamping element, which remains in the tool holder. This allows the cutting insert to be replaced independently without replacing the seal, while the sealing function is maintained through the clamping element's integrated seal.
Solution Approach 2:
The clamping element acts as an intermediary component between the cutting insert and the tool holder, incorporating the sealing function. This mediator ensures fluid-tight connection while allowing independent replacement of the cutting insert, separating the maintenance cycles of these components.
2Duration of action of moving object
If coolant is supplied under high pressure to cool the processing area, then cutting tool life is extended, but the sealing requirements at the interface become more stringent
Solution Approach 1:
The sealing function is merged with the clamping element structure itself, rather than being a separate component. This integration ensures that the seal is designed specifically for high-pressure coolant applications and maintains reliability under the demanding conditions of high-pressure cooling.
3Manufacturing precision
If the clamping element is designed with angled contact surfaces for secure positioning, then machining precision is improved, but the device complexity increases
Solution Approach 1:
The angled contact surfaces are applied locally at specific interfaces of the clamping element where positioning is required, rather than complicating the entire structure. This localized application of geometric features achieves precise insert positioning without unnecessarily increasing overall device complexity.
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 system enhances cutting tool life and machining efficiency by optimizing cooling in the shear zone, enabling increased machining parameters and reduced manufacturing costs through precise coolant delivery and secure clamping of the cutting insert.
Implementation Method 1
a sealant for the pressure-tight connection of the fluid channels being arranged in the area of the interface between the tool holder and the clamping element
Implementation Method 2
the tool holder and the clamping element having at least one fluid channel for cooling
Implementation Method 3
Through targeted cooling in the shear zone of chip formation in the range from 800 to 1100°
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
Tool system 1 with a tool holder 2 having a plate seat 17 for receiving a cutting insert 6, with a clamping element 4 having an opening 26 for receiving a clamping device 15, wherein an interface 30 is arranged between the tool holder 2 and the clamping element 4 and channels for cooling by means of a fluid are arranged in the tool holder 2 and the clamping element 4 and wherein a sealing agent 31 is arranged in the area of the interface 30.