Grooved Coolant Channels in Cutting Tools for Insert Strength
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Solution Overview
Problem
Conventional cutting tools with coolant flow channels complicate manufacturing and weaken the cutting insert, while existing methods for delivering coolant to cutting edges often interfere with the strength of the insert.
Innovation Solution
A cutting tool with internal coolant channels featuring grooves aligned with the flow direction to enhance coolant flow, and a nozzle with a single through hole and internal coolant channels that follow a smooth path to minimize obstruction, allowing for efficient coolant delivery without compromising the tool's strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If coolant flow channels are provided in the cutting inserts, then coolant delivery to cutting edges is improved, but manufacturing complexity increases and strength decreases
Solution Approach 1:
The coolant channel is segmented into multiple sections with grooves at different orientations. The grooves are divided into a first section (axially oriented) and a second section (radially oriented), allowing each segment to serve a specific function in optimizing coolant flow while maintaining manufacturing feasibility.
Solution Approach 2:
Different sections of the coolant channel have different groove orientations tailored to local flow requirements. The axial grooves dominate in the first section where straight flow is needed, while radial grooves dominate in the second section where flow distribution is needed, optimizing coolant delivery locally throughout the channel.
2Reliability
If coolant flow channels are provided in the cutting inserts, then coolant delivery to cutting edges is improved, but strength of the cutting insert decreases
Solution Approach 1:
The groove structure is optimized locally within the coolant channel to enhance coolant flow only where needed, while the rest of the cutting insert maintains its full structural integrity. The grooves are confined to specific sections rather than penetrating the entire insert, preserving strength.
3Reliability
If grooves are added to coolant channels, then coolant flow properties are enhanced, but flow obstruction increases
Solution Approach 1:
The grooves are segmented into different orientations (axial and radial) and distributed along different sections of the channel. This segmentation allows the grooves to enhance flow properties through controlled turbulence and mixing while preventing excessive flow obstruction by distributing the groove effects throughout the channel length.
Solution Approach 2:
The groove parameters (orientation, size, distribution) are optimized to change along the channel length. The axial grooves in the first section promote straight flow, while radial grooves in the second section enhance mixing and distribution, with parameters tuned to balance flow enhancement against obstruction.
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
The solution enables effective coolant delivery to cutting edges, reducing manufacturing complexity and maintaining tool strength, leading to improved coolant flow and increased tool life by reducing friction and cutting temperature.
Implementation Method 1
grooves extending internally at least partially along the coolant channel for enhanced flow properties
Implementation Method 2
the direction of the grooves coincides with the flow direction at least along half of the length of the coolant channel to reduce obstruction of the flow of coolant
Implementation Method 3
the coolant channel has a changing cross-section to divide the volumetric flow of the coolant
Implementation Method 4
the size of a second opening of the coolant channel defines the smallest diameter of the coolant channel such to increase coolant speed
Implementation Method 5
coolant cools the cutting insert
Implementation Method 6
minimizing the heat accumulated due to the interaction of a cutting insert with a machined workpiece
Data Source
AI summary
The present disclosure relates to a cutting tool for metal chip removing machining having at least one internal coolant channel for fluid having a flow direction. The at least one internal coolant channel having a length and including a plurality of grooves extending internally at least partially along the coolant channel.