Cutting Tool Lubrication Orifices Using Removable Polymer Inserts
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Solution Overview
Problem
Existing cutting tools with lubrication orifices are complex and costly to produce, limited to producing simple shapes due to the hardness of high-strength steels, and are restricted to use in grinding applications on materials with hardness below a certain threshold.
Innovation Solution
A method for manufacturing a cutting tool with lubrication orifices of complex shapes involves producing a polymer insert, overmoulding the cutting tool body with the insert, removing the insert to form complementary lubrication orifices, sintering the body, machining the active part, and depositing an abrasive coating on the active surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high-strength steel is used for the cutting tool body, then strength and hardness are improved, but manufacturing complexity and cost increase significantly
Solution Approach 1:
The cutting tool is divided into two distinct parts: a polymer insert containing the complex lubrication orifices and a sintered metal body providing structural strength. This segmentation allows each component to be optimized independently - the polymer for complex internal geometry and the metal for mechanical properties - thereby reducing overall manufacturing complexity while maintaining strength.
Solution Approach 2:
The invention uses a composite structure combining polymer and sintered metal materials. The polymer insert provides the lubrication channels while the sintered metal body provides the required mechanical strength. This composite approach enables complex internal geometries that would be impossible to machine in solid metal, while maintaining the necessary structural integrity.
2Strength
If high-strength steel is used for the cutting tool body, then strength is improved, but lubrication orifice shape complexity is limited
Solution Approach 1:
By separating the lubrication orifice structure from the tool body, the invention allows complex three-dimensional orifice geometries to be formed within the polymer insert using additive manufacturing or injection molding, while the metal body maintains its structural strength without machining constraints.
Solution Approach 2:
The invention changes the material parameter from solid metal to polymer for the orifice-containing component, enabling complex shapes that cannot be achieved through traditional machining of metal. The polymer material allows for intricate internal geometries to be formed during manufacturing rather than requiring complex post-processing.
3Ease of manufacture
If traditional machining methods are used, then manufacturing process is simple, but application range is limited to materials with hardness below certain threshold
Solution Approach 1:
The composite structure with optimized lubrication delivery enables the cutting tool to effectively machine hard materials such as ceramics and hardened metals. The polymer insert with complex internal channels provides superior lubrication and cooling that overcomes the limitations of traditional tools when working with high-hardness materials.
Solution Approach 2:
The invention changes the lubrication delivery parameters through complex internal orifice geometries, enabling effective coolant and lubricant delivery to the cutting interface. This allows the tool to maintain effective operation when machining materials with hardness above traditional thresholds by optimizing the lubrication regime.
4Reliability
If complex lubrication orifices are produced, then lubrication optimization is improved, but manufacturing cost and complexity increase
Solution Approach 1:
By isolating the complex lubrication orifice structure into a separate polymer insert, the invention allows complex geometries to be manufactured using additive manufacturing or injection molding processes. This segmentation transfers the manufacturing complexity from precision metal machining to polymer fabrication, which can more easily accommodate complex internal geometries.
Solution Approach 2:
The invention replaces traditional mechanical machining methods with additive manufacturing or injection molding for producing the polymer insert. This substitution enables complex three-dimensional orifice networks to be created directly during manufacturing rather than requiring complex drilling, milling, and tapping operations.
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 method enables the production of cutting tools with complex lubrication orifices, allowing for machining of hard materials like ceramics and hard metals, and optimizing lubrication for milling operations, thereby expanding the tool's applicability beyond traditional limitations.
Implementation Method 1
overmoulding 310 a body of the cutting tool with the polymer insert by injecting into a mould
Implementation Method 2
removing 320 the polymer insert, so as to form in the body of the cutting tool lubrication orifices
Implementation Method 3
sintering 330 the body of the cutting tool 10
Implementation Method 4
depositing an abrasive coating 350 on a surface of the active part of the body of the cutting tool
Data Source
AI summary
A method for manufacturing a cutting tool (10) with lubrication orifices of complex shapes, including the steps of: producing a polymer insert (20), overmoulding a body of the cutting tool (10) with the polymer insert (20) by injecting into a mould, removing the polymer insert (20), so as to form in the body of the cutting tool (10) lubrication orifices, the shape whereof is complementary with that of a part of the insert (20), machining the body of the cutting tool (10) on an active part thereof, and depositing an abrasive coating on a surface of the active part of the body of the cutting tool (10).