Cutting Tool Air Flow for Powder Removal in Metal Additive Manufacturing
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Solution Overview
Problem
Existing metal powder processing equipment faces issues with unmolded powder and cut powder remaining on the cutting tool, leading to reduced tool life, damage, and poor surface quality during laser or electron beam melting and cutting processes.
Innovation Solution
The equipment generates an air flow along the side surface of the cutting tool, using air flow pass holes and angled jet exits to scatter unmolded powder and cut powder, preventing them from adhering to the cutting edge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If cutting process is continued in a state where unmolded powder and cut powder remain, then productivity is maintained, but cutting tool life is extremely shortened and tool damage occurs
Solution Approach 1:
The patent applies preliminary action by introducing air flow through holes in the cutting tool before the powder accumulation becomes problematic. The air flow proactively removes unmolded powder and cut powder from the cutting edge area, preventing powder buildup that would otherwise lead to tool damage and shortened tool life, thereby maintaining both productivity and tool reliability
Solution Approach 2:
The patent utilizes pneumatics by employing air flow generated through the cutting tool structure itself. Holes are formed in the cutting tool to allow air to pass through and blow away powder particles from the cutting edge, providing an effective powder removal mechanism that extends tool life without interrupting the cutting process
2Productivity
If cutting process is executed with unmolded powder and cut powder present, then processing efficiency is maintained, but cut surface quality deteriorates and smooth surface cannot be obtained
Solution Approach 1:
The patent employs pneumatic action through air flow channels integrated into the cutting tool. The air flow continuously clears powder particles from the cutting zone, ensuring that the cut surface remains free from powder contamination and achieves the desired smoothness and quality while maintaining processing efficiency
3Object-generated harmful factors
If air flow is used to remove powder after cutting, then powder removal is achieved, but equipment structure and control become complicated
Solution Approach 1:
The patent merges the powder removal function with the cutting tool structure itself. The air flow holes are integrated directly into the cutting tool body, combining the cutting and powder removal functions into a single integrated component. This eliminates the need for separate powder removal equipment and simplifies the overall system structure while maintaining effective powder removal
Solution Approach 2:
The cutting tool serves itself by incorporating air flow holes that enable it to remove its own generated powder. The tool structure includes internal passages that allow air to flow through and clear powder from the cutting edge, making the tool self-cleaning and eliminating the need for external powder removal systems
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 configuration prolongs the life of the cutting tool, improves surface quality, and reduces processing time by ensuring smooth operation and effective removal of powders.
Implementation Method 1
generates an air flow to a side surface of the cutting tool which rotates along a central axis of the cutting tool and which flows the air in a longitudinal direction of the cutting tool
Data Source
AI summary
In metal powder processing equipment where metal powder is sequentially laminated on a table inside a chamber and laser beam melting or electron beam melting, and shaping by a cutting tool subsequent to the melting are performed, unmolded powder remaining at the time of the melting and cut powder generated by the cutting can be scattered by generating air flow with respect to the cutting tool from either side of a main shaft or a tool holder. As a result, life of the cutting tool is prolonged and quality of a cut surface can be improved.