Additive Laser-Melted Cutting Tool Holder Joined to Base Body
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Solution Overview
Problem
The existing hybrid construction of cutting tools, which combines materials with different chemical compositions, often results in internal stresses leading to potential cracking and detachment during production, especially when using additive manufacturing for the blade carrier, causing manufacturing interruptions and damage.
Innovation Solution
The solution combines additive and subtractive methods by prefabricating the blade carrier separately and connecting it to a subtractively manufactured base body via laser welding, with heat treatment and form-fitting elements to minimize stress and enhance tool life, and incorporates coolant channels and optimized cutting element attachment for improved performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the cutting tool holder is additively manufactured directly onto the base body, then complex geometries can be realized, but internal stresses cause cracking and detachment
Solution Approach 1:
The cutting tool holder is separated from the base body into two independently manufactured components. The holder is additively manufactured separately on a build platform, then permanently joined to the subtractively manufactured base body via laser welding at a joint. This segmentation allows each component to be optimized independently, reducing internal stresses that would occur with direct hybrid construction.
Solution Approach 2:
Laser welding serves as an intermediary joining method between the additively manufactured cutting tool holder and the subtractively manufactured base body. The laser welding process introduces minimal heat locally, keeping stresses in the joint area low while creating a strong permanent connection, thus acting as a mediator that bridges two different manufacturing processes without transferring harmful stresses.
2Ease of manufacture
If conventional manufacturing methods are used for the cutting tool holder, then manufacturing is simpler, but complex topologies cannot be realized
Solution Approach 1:
The manufacturing process is segmented into two separate operations: additive manufacturing for the cutting tool holder and subtractive manufacturing for the base body. This allows the holder to achieve complex topologies through additive processes while the base body is manufactured using conventional subtractive methods, combining the advantages of both approaches.
Solution Approach 2:
Different manufacturing parameters and processes are applied to different components based on their functional requirements. The cutting tool holder uses additive manufacturing parameters that enable complex geometries, while the base body uses subtractive manufacturing parameters optimized for structural integrity and precision, allowing each component to be manufactured in the most suitable way.
3Temperature
If laser welding is used to join the cutting tool holder to the base body, then heat input is minimized, but additional process steps are required
Solution Approach 1:
Traditional mechanical joining methods or high-heat welding processes are replaced with laser welding technology. The laser welding process delivers concentrated energy with minimal heat input to the joint area, avoiding uncontrolled hardening and adverse microstructural changes while maintaining strong joint integrity.
Solution Approach 2:
The welding process parameters are optimized to achieve minimal heat input. By controlling laser power, speed, and focus, the process achieves adequate penetration and strength while limiting the heat-affected zone. This parameter optimization balances the trade-off between joint quality and thermal effects.
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 reduces the risk of warping and structural changes, enhances tool reliability and longevity, and allows for sophisticated topologies while maintaining cost-effectiveness and process efficiency.
Implementation Method 1
the cutting tool holder is permanently joined to the subtractively manufactured base body at a joint by laser welding
Implementation Method 2
the cutting tool holder, in conjunction with the base body, undergoes heat treatment by heating to at least 400°C, preferably around 500°C. This ensures that the component remains largely stress-free and prevents a loss of hardness
Implementation Method 3
in selective laser melting, the powder material is applied to the build platform in superimposed layers and melted layer by layer in a predetermined component geometry using laser radiation
Data Source
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AI summary
The invention relates to a machining cutting tool (10) and a method for the production thereof, wherein a base body (12), preferably made of a tool steel, and which can be accommodated in a machine tool, is brought into a final shape via separation, a cutting tool carrier (16) is additively constructed from a powder material by means of selective laser melting, and the cutting tool carrier (16) is provided with at least one cutting element (18), wherein the cutting tool carrier (16) is additively prefabricated separately from the base body (12) on a construction platform (34), and subsequently, the cutting tool carrier (16) is securely connected to the base body (12) at a joining point (14) by means of laser welding.