Cutting Tool Coolant Chamber With Integrated Deflection Flow
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Solution Overview
Problem
Existing cutting tools with cooling mechanisms face limitations in coolant distribution, particularly in traditional manufacturing methods where coolant ducts are post-manufactured, restricting their structure and efficiency.
Innovation Solution
The cutting tool features an Additively Manufactured tool body with a coolant chamber that is recessed and has an elongated, non-circular shape, allowing for efficient coolant distribution directly to the cutting edge, with two coolant ducts extending on either side of the threaded bore and a coolant deflection portion that directs coolant over the relief surface, enhancing coolant impact on the cutting edge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional manufacturing methods are used to create coolant ducts by post-manufacturing drilling, then the manufacturing process is simpler and more established, but the coolant duct structure is restricted and cannot achieve optimal coolant distribution
Solution Approach 1:
The patent merges the coolant duct structure with the tool body by integrating the deflecting portion directly into the tool body structure. This allows the coolant duct to be formed as a unified component during additive manufacturing, eliminating the need for separate post-manufacturing drilling operations while achieving complex internal geometries that optimize coolant distribution to the cutting edge.
Solution Approach 2:
The patent transitions from traditional 2D/3D manufacturing constraints to 4D printing capabilities, allowing the coolant duct to have complex spatial configurations including curved paths and variable cross-sections that cannot be achieved with conventional drilling. The deflecting portion extends into new spatial dimensions within the tool body, enabling coolant to be directed at optimal angles to the cutting edge.
2Manufacturing precision
If Additive Manufacturing is used to create coolant ducts with unusual structures, then coolant distribution efficiency is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent combines the tool body manufacturing with the coolant duct formation into a single additive manufacturing process. The deflecting portion is integrated into the tool body as a unified structure, allowing both components to be manufactured simultaneously in one process step, thereby reducing overall manufacturing complexity despite the advanced geometry required.
Solution Approach 2:
The additive manufacturing process serves multiple functions: it creates the tool body structure, forms the coolant ducts with complex geometries, and integrates the deflecting portion all in one operation. This multi-functionality reduces the need for multiple separate manufacturing steps and post-processing operations.
3Productivity
If coolant outlets are positioned in traditional locations, then the tool design is simpler, but coolant flow obstruction from metal chips occurs and cutting performance decreases
Solution Approach 1:
The patent repositions the coolant outlet from traditional locations to a coolant chamber that opens at the rear of the tool body, utilizing the z-dimension (depth) rather than just radial positioning. This rearward positioning places the outlet in a location less susceptible to chip obstruction, allowing coolant to flow more effectively to the cutting edge throughout the cutting cycle.
Solution Approach 2:
The coolant chamber is positioned and configured to deliver coolant to the cutting edge before chips can accumulate and block the flow path. The deflecting portion is pre-shaped to direct coolant along the intended flow path, ensuring coolant reaches the cutting zone before obstruction occurs during 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
This configuration ensures effective coolant delivery to the cutting edge, improving cutting performance by maintaining coolant flow and reducing obstruction from metal chips, while being impossible to achieve with traditional manufacturing methods.
Implementation Method 1
a coolant chamber (44) that is closed at one end and opens out to the tool body surface (26) at a coolant chamber opening (46) spaced apart from the insert pocket (28) by an opening distance D. The coolant chamber (44) is designed to direct coolant fluid towards the cutting edge (38) of the cutting insert (22) with which it is associated.
Implementation Method 2
The chamber deflection surface (50) is located on a coolant deflection portion (58), which is connected to the tool body (24) and has unitary one-piece construction therewith. The coolant deflection portion (58) overhangs the outlet orifice (56) in a direction towards the insert pocket (28).
Implementation Method 3
Alternatively the tool body can be manufactured by newer techniques, such as Additive Manufacturing. Additive Manufacturing refers to a class of manufacturing processes, in which a part is built by adding layers of material upon one another.
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A cutting tool (20) includes a replaceable cutting insert (22) and a tool body (24). The tool body (24) includes a tool body surface (26) and an insert pocket (28) recessed therein. The cutting insert (22) is releasably retained in the insert pocket (28). The tool body (26) includes at least one coolant duct (60a, 60b) that has an outlet orifice (56) that opens out in a coolant chamber (44). The coolant chamber (44) is bounded on a side opposite the outlet orifice (56) by a coolant deflection portion (58) that is integrally formed with the tool body (26) in a unitary one-piece construction and at least partially overhangs the outlet orifice (56) in a direction (P) towards the insert pocket (28).