Laser-Cut Drill Bit Chip Breaker for Continuous Chip Control
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Solution Overview
Problem
Conventional drill bits face difficulties in handling continuous chips from ductile non-ferrous materials, leading to increased cutting forces and potential tool damage, as existing chip breakers are limited in size and shape due to manufacturing constraints, particularly with polycrystalline diamond (PCD) tools where electro discharge machining (EDM) is not viable.
Innovation Solution
A drill bit with a laser-cut chip breaker featuring a groove with varying angles and depths, positioned behind the cutting edge, which is designed to break continuous chips into smaller pieces, reducing cutting forces and preventing chip tangling, utilizing laser cutting to achieve complex geometries not possible with EDM.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional electro discharge machining (EDM) is used to create chip breakers, then manufacturing precision can be achieved, but the chip breaker size and shape are limited and cannot achieve complex geometries
Solution Approach 1:
The patent replaces the conventional electro discharge machining (EDM) mechanical system with a laser-based system. The laser cutting method uses optical energy instead of electrical discharge to create chip breakers, enabling complex geometries and varied shapes that were not achievable with EDM while maintaining manufacturing precision
Solution Approach 2:
The invention changes the manufacturing parameter from electrical discharge to laser cutting. This parameter change allows for variable chip breaker sizes and shapes by adjusting laser parameters such as power, speed, and focal position, thereby achieving adaptability in chip breaker geometry while preserving manufacturing precision
2Productivity
If chip breakers are made larger to break continuous chips, then chip breaking effectiveness improves, but cutting forces increase and may damage the tool
Solution Approach 1:
The laser-cut chip breaker implements local quality by creating a groove with varying depth and angle along its length. The groove is deeper and more aggressive at the entry point to effectively break continuous chips, then transitions to a shallower section to reduce cutting forces. This localized variation in groove geometry optimizes both chip breaking effectiveness and force reduction
Solution Approach 2:
The chip breaker groove features curved and angled surfaces rather than straight lines. The groove has a contoured profile with varying angles that smoothly guide the chip through the breaking zone, reducing abrupt force changes while maintaining effective chip breaking action
3Productivity
If continuous chips are produced from ductile non-ferrous materials, then material removal is efficient, but chips tangle and clog the drill hole reducing productivity
Solution Approach 1:
The laser-cut chip breaker extracts the continuous chip from the drill hole by creating a groove that lifts and breaks the chip away from the cutting zone. The groove geometry is designed to catch and elevate the continuous chip, breaking it into smaller segments that can be easily evacuated through the flutes, thus eliminating the clogging problem while preserving efficient material removal
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 laser-cut chip breaker enhances chip removal efficiency, prolongs tool life, and prevents chip clogging, allowing for smoother cutting operations by effectively breaking continuous chips and minimizing cutting forces.
Implementation Method 1
A drill bit with a laser-cut chip breaker featuring a groove with varying angles and depths, positioned behind the cutting edge
Data Source
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AI summary
A drill bit for a drill includes at least one flute having a rake face (32) including a flute edge and at least one cutting edge (20, 22) having a profile that extends along at least a portion of a length of the cutting edge, the rake face extending from the cutting edge. A chip breaker (40) formed in the rake face, the chip breaker being a continuous groove located adjacent the cutting edge, the groove having a starting end and an exit end opening into the flute edge, the starting end having a depth that is less than a depth of the exit end of the groove, wherein a shape of the groove at the starting end is different from a shape of the groove at the exit end.