Cutting Tool Chip Passage Structure for Reliable Bore Chip Removal
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Solution Overview
Problem
Current cutting tools face challenges in reliably guiding and removing chips from the processing space during machining, leading to potential chip accumulation and surface quality issues, especially in complex components like engine blocks.
Innovation Solution
A cutting tool design featuring a clamping shank with a tool carrier and cutting head that includes a radially limited chip-receiving space, formed by passage surfaces and a circumferential wall, which prevents chips from re-entering the processing area and ensures efficient coolant flow for chip removal, utilizing additive manufacturing for a one-piece construction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional cutting tools with open chip discharge paths are used, then chip removal is possible, but chips can re-enter the processing space and accumulate, deteriorating surface quality
Solution Approach 1:
The chip discharge path is segmented into distinct functional zones: a closed chip-receiving space separated from the processing area by a circumferential wall, passage surfaces for controlled chip flow, and a chip outlet opening positioned away from the processing zone. This segmentation prevents chips from re-entering the bore while maintaining reliable discharge.
2Reliability
If a closed chip-receiving space with circumferential wall is implemented, then chips are prevented from re-entering processing area, but tool structure becomes more complex
Solution Approach 1:
The chip-receiving space, circumferential wall, passage surfaces, and coolant ducts are merged into a single integrated tool carrier body manufactured by additive manufacturing. This consolidation achieves reliable chip containment while eliminating the complexity of assembling multiple separate components.
Solution Approach 2:
Additive manufacturing enables the realization of complex geometric parameters including the circumferential wall configuration, passage surface orientations, and integrated coolant duct pathways that would be difficult or impossible to achieve with conventional manufacturing methods.
3Temperature
If coolant ducts are integrated in the circumferential wall, then cooling efficiency is improved, but manufacturing difficulty increases
Solution Approach 1:
Additive manufacturing fundamentally changes the manufacturing capability parameters, enabling the creation of complex internal coolant duct geometries within the circumferential wall that cannot be achieved with traditional subtractive or formative manufacturing processes.
Solution Approach 2:
Coolant ducts are nested within the circumferential wall structure, with coolant channels positioned concentrically or adjacently to the wall. This nested arrangement maximizes cooling efficiency by placing coolant flow paths close to the cutting edges while maintaining structural integrity.
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 design effectively prevents chip accumulation, maintains high surface quality, reduces heat generation, and extends tool lifespan by ensuring reliable chip discharge and efficient coolant distribution, minimizing the risk of chips re-entering the bore during processing.
Implementation Method 1
at least one coolant duct, which is provided to guide coolant to the cutting head end
Implementation Method 2
a respective chip passage, which feeds into the chip-receiving space and which is limited by a chip gap
Data Source
AI summary
A cutting tool comprising at least one blade arranged at an axial cutting head end of a tool carrier. The tool carrier comprises a chip-removal space that receives material chips removed by the blade. In some embodiments, the blade is adjacent to a chip passage feeding into the chip-removal space, which passage is limited by a radial chip gap partially limited by the blade and from there by a first and second passage surface, the first passage surface a continuation of the chip surface of the blade, the second passage surface running at an angle and widening relative to same, and is closed and limited at least in an axial sub-section facing the cutting head end, all around by a peripheral wall as a third passage surface, wherein at least one coolant channel is formed within the peripheral wall, which is provided to guide coolant to the cutting head end.