Generative Cutting Tool Base Bodies with Internal Dampening
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Solution Overview
Problem
Traditional cutting tool manufacturing methods are inefficient due to long manufacturing and delivery times, restricted coolant-lubricant supply, limited vibration dampening, and restricted signal or power lead arrangeability, especially for complex geometries.
Innovation Solution
The use of generative production processes like Selective Laser Melting (SLM) and Direct Metal Deposition to create tool base bodies and holders with complex geometries, including flow-optimized coolant ducts and internal vibration dampening cavities, allowing for optimized mechanical properties and reduced manufacturing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional cutting machining methods are used to produce tool base bodies, then manufacturing precision can be achieved, but manufacturing time and delivery time are excessively long
Solution Approach 1:
The patent combines multiple traditional machining operations (turning, milling, drilling, grinding, thread production) and material treatment processes (nitriding, hardening) into a single generative production step using Selective Laser Melting technology, thereby dramatically reducing manufacturing time while maintaining the required tool geometry precision through digital model control
Solution Approach 2:
The patent changes the fundamental manufacturing parameter from sequential mechanical machining to additive generative production using laser melting, transforming the production approach from subtractive to additive manufacturing, which enables complex geometries to be produced in one step rather than through multiple operations
2Adaptability or versatility
If traditional machining methods are used, then standard tool geometries can be produced, but complex geometries and optimized coolant supply paths are restricted
Solution Approach 1:
The patent enables local optimization of tool geometry and coolant supply paths by using generative production to create flow-optimized coolant ducts and recesses specifically positioned where needed, allowing different regions of the tool to have tailored geometries optimized for their specific functional requirements
Solution Approach 2:
The patent utilizes the third dimension extensively by creating complex three-dimensional coolant ducts and internal structures within the tool base body that cannot be achieved through traditional two-dimensional machining approaches, enabling optimized coolant flow paths through the entire tool volume
3Reliability
If traditional tool structures are used, then simple designs can be manufactured, but vibration dampening and signal lead arrangeability are limited
Solution Approach 1:
The patent incorporates vibration dampening cavities with porous or honeycomb-like internal structures within the tool base body, which provide effective vibration dampening through the porous material's energy absorption characteristics while being integrated into the overall tool structure through generative production
Solution Approach 2:
The patent nests multiple functional elements including coolant ducts, vibration dampening cavities, and signal lead channels within the tool base body structure, creating a nested arrangement where different functional components are integrated concentrically or adjacently within the same structural volume
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 approach enables rapid, cost-effective production of cutting tools with unrestricted geometrical design, improved vibration dampening, and efficient coolant supply, reducing manufacturing time and material usage while allowing for complex geometries and localized material optimization.
Implementation Method 1
paths for layer-wise generation of solid structures are generated on the basis of 3D geometry data of any geometry. For the generation of the component, a thin layer of metallic powder is applied using a scraper. The thickness of the layer depends on the powder grain size used, the material used and the laser source. Using a laser beam, the powder is locally molten up
Implementation Method 2
the powder is locally molten up, thereby combining with the underlying solid material. Thus, powderous material can be solidified layer-wise and any geometry procuded on the basis of 3D geometry data
Data Source
AI summary
A method for the manufacture of a cutting tool provided with a tool holder (1) to which a cutter (2) is separably attached, includes applying a generative production process to a tool base body (3) to create the tool holder (1) with a desired finished shape.