Additively Formed Drill Head for Shorter Chip Formation
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Solution Overview
Problem
Existing drill heads face limitations in design freedom due to grinding processes, which can lead to long chip formation that clogs chip flutes, particularly problematic in drilling, where long chips are undesirable.
Innovation Solution
A drill head manufactured using additive or primary forming methods, such as injection molding, allowing for the creation of complex geometries and structural elements that act as chip breakers, guides, and friction reduction features, enabling the design of shorter chips and improved machining performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If grinding methods are used to manufacture drill head geometries, then manufacturing precision can be achieved, but design freedom is limited
Solution Approach 1:
The patent replaces traditional mechanical grinding methods with additive manufacturing technology. This substitution enables the creation of complex drill head geometries including internal channels, variable pitch helices, and optimized chip flute structures that cannot be achieved through conventional grinding, thereby resolving the contradiction between manufacturing precision and design freedom.
Solution Approach 2:
The patent utilizes additive manufacturing to enable continuous variation of geometric parameters along the drill head structure, such as variable cross-sectional areas, changing helix angles, and non-uniform chip flute configurations. This parameter flexibility allows optimization of chip breaking and removal while maintaining manufacturing precision.
2Device complexity
If conventional drill head design is used, then simplicity is maintained, but long chips are formed that clog chip flutes
Solution Approach 1:
The patent segments the chip flute into multiple zones with different geometric characteristics. The chip flute cross-sectional area varies along its length, with wider sections for chip accumulation and narrower sections for chip breaking. Internal partitions and transverse flutes divide the chip flow path, preventing long chip formation and clogging while managing chip evacuation efficiently.
Solution Approach 2:
The patent introduces three-dimensional geometric features including variable cross-sectional areas, spiral internal channels, and multi-level chip flute structures. These dimensional variations create complex chip flow paths that break chips into manageable segments and prevent clogging, transforming the simple two-dimensional chip flute concept into a multi-dimensional chip management system.
3Adaptability or versatility
If additive manufacturing is used to create complex geometries, then design freedom is enhanced, but manufacturing complexity increases
Solution Approach 1:
The patent combines multiple functional features into a single integrated drill head structure manufactured in one additive process. Chip flutes, internal cooling channels, chip breaking elements, and structural support features are merged into one monolithic component, eliminating the need for separate manufacturing steps and assembly operations, thereby reducing manufacturing complexity despite geometric complexity.
Solution Approach 2:
The additive manufacturing process enables the drill head to perform multiple functions simultaneously: cutting, chip breaking, chip evacuation, and coolant delivery, all within a single geometric structure. This multi-functionality is achieved through integrated design where different regions of the drill head serve different purposes, reducing the need for separate components and simplifying the overall manufacturing process.
Data Source
AI summary
The invention relates to a drill head comprising at least one surface, with a number of structural elements, wherein the structural elements are manufactured by an additive or primary forming manufacturing method. The invention further relates to a method for manufacturing such a drill head.