Cutting Insert Shim With Internal Coolant Delivery
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Solution Overview
Problem
In chipforming material removal operations, excessive heat at the insert-chip interface reduces tool life, leads to premature breakage and wear, and causes chip sticking and re-cutting issues due to inadequate coolant delivery.
Innovation Solution
A cutting insert-shim-holder assembly with internal coolant delivery systems that provide enhanced coolant flow to the insert-chip interface, featuring multiple coolant channels, variable channel areas, and adjustable diversion angles to maximize coolant delivery and prevent chip sticking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If conventional cutting inserts without internal coolant delivery are used, then the device complexity is low, but excessive heat at the insert-chip interface reduces tool life and causes premature breakage and wear
Solution Approach 1:
The patent implements internal coolant delivery channels nested within the cutting insert body itself. The coolant passages are integrated into the insert structure, allowing coolant to be delivered directly to the insert-chip interface from within the insert, rather than requiring external delivery systems. This nesting approach extends tool life by effectively cooling the interface while minimizing additional complexity through integration.
Solution Approach 2:
The patent introduces coolant as an intermediary substance that mediates heat transfer at the insert-chip interface. The coolant flows through internal channels and exits at the cutting edge, directly cooling the interface between the insert and workpiece. This intermediary coolant system addresses the heat problem while the internal channel design keeps the overall system complexity manageable.
2Reliability
If conventional cutting inserts without internal coolant delivery are used, then the device complexity is low, but heat causes increased wear and plastic deformation resistance decrease
Solution Approach 1:
The coolant delivery channels are nested within the cutting insert body, allowing direct coolant delivery to the insert-chip interface. This internal cooling system maintains the insert's reliability by preventing excessive heat that would cause plastic deformation and wear, while the integrated design minimizes added complexity.
Solution Approach 2:
The patent utilizes hydraulic principles by flowing coolant through internal channels to the cutting interface. The coolant flow, driven by hydraulic pressure, delivers cooling directly to the insert-chip interface, maintaining material resistance properties by controlling temperature. This hydraulic approach provides effective cooling without requiring complex mechanical cooling systems.
3Ease of operation
If conventional cutting inserts without internal coolant delivery are used, then the device complexity is low, but chip sticking and re-cutting issues occur due to inadequate coolant delivery
Solution Approach 1:
The internal coolant channels are nested within the insert structure, delivering coolant directly to the chip formation zone at the insert-chip interface. This direct internal cooling prevents chip sticking by maintaining proper lubrication and temperature conditions during chip formation, while the integrated design keeps complexity low.
Solution Approach 2:
The coolant is delivered preliminarily to the insert-chip interface before chips can stick or re-cutting can occur. The internal channels position the coolant delivery point exactly where it is needed at the cutting edge, preventing chip adhesion and ensuring smooth chip evacuation from the outset of the cutting operation.
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 assembly significantly extends tool life by reducing heat and wear, improving lubrication, and preventing chip re-cutting through efficient coolant distribution, allowing for flexible operation in various material removal processes without additional components.
Implementation Method 1
enhanced delivery of coolant adjacent the interface between the cutting insert and the workpiece (i.e., the insert-chip interface) to diminish excessive heat at the insert-chip interface
Implementation Method 2
enhanced lubrication at the insert-chip interface is a decrease in the tendency of the chip to stick to the cutting insert
Data Source
AI summary
A cutting insert-shim assembly that has a cutting insert with a bottom surface and a plurality of interior coolant passages wherein each interior coolant passage has a coolant inlet in the bottom surface of the cutting insert. The shim has a first side surface and a second side surface and contains a cavity, which communicates with the coolant conduit. The cavity defines a first opening in the first side surface and a second opening in the second side surface. When the shim is in a first condition, the first side surface contacts the bottom surface of the cutting insert and the first opening provides a first level of coolant communication to the interior coolant passages in the cutting insert. When the shim is in a second condition, the second side surface contacts the bottom surface of the cutting insert and the second opening provides a second level of coolant communication to the interior coolant passages in the cutting insert.