3D Printed Machining Tool with Porous Core
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Machining tools, such as drills, face challenges in achieving efficient material use and maintaining mechanical stability while minimizing weight and material usage.
Innovation Solution
A machining tool with a monolithic base body featuring a non-solid core structure encased in a solid outer jacket, manufactured using 3D printing, which allows for complex geometries and efficient material distribution, providing mechanical support and stability through a porous, grid-like, or bionic core design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a solid base body is used in machining tools, then mechanical stability is improved, but material usage and weight increase
Solution Approach 1:
The base body is designed with a porous core structure that provides mechanical stability while reducing material usage. The porous structure allows coolant flow paths to be integrated within the base body itself, eliminating the need for separate coolant channels while maintaining structural integrity through the strategic distribution of porous regions.
Solution Approach 2:
The base body is segmented into regions of different porosity - a porous core structure surrounded by a solid outer jacket. This segmentation allows different parts of the base body to serve different functions: the porous core for coolant flow and weight reduction, and the solid outer jacket for mechanical strength and stability.
2Strength
If a solid base body is used in machining tools, then mechanical stability is improved, but weight increases
Solution Approach 1:
The porous core structure reduces the density of the base body while maintaining sufficient mechanical stability through the surrounding solid outer jacket. This density reduction directly decreases the overall weight of the machining tool while preserving the necessary structural properties for stable operation.
Solution Approach 2:
The base body functions as a composite structure combining porous material in the core region with solid material in the outer jacket. This composite approach optimizes the weight-strength ratio by placing material only where structurally necessary, reducing overall weight while maintaining mechanical stability.
3Temperature
If coolant channels are formed in the base body, then cooling efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
Instead of forming discrete coolant channels, the base body incorporates a porous core structure that allows coolant to flow through the material matrix itself. This approach integrates the cooling function directly into the base body structure, improving cooling efficiency while avoiding the manufacturing complexity of drilling and machining separate coolant passages.
Solution Approach 2:
The cooling function is merged with the base body structure itself rather than being a separate component. The porous core structure serves dual purposes: providing structural support and enabling coolant flow, thereby combining multiple functions into a single integrated element and simplifying manufacturing.
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 design achieves significant material savings while maintaining high mechanical stability and enabling efficient coolant flow, resulting in a more stable and efficient machining tool with improved rotational performance.
Implementation Method 1
processing a powdery starting material layer-by-layer with a laser, such that the individual powder particles bond to one another, for example, melt with or sinter with one another layer-by-layer into a solid, rigid body
Implementation Method 2
melt with or sinter with one another layer-by-layer into a solid, rigid body
Data Source
AI summary
A machining tool, in particular a drill carrier tool, includes a monolithic base body extending in the axial direction which, at least in one section, has a porous or grid-like core structure that is encased in a solid outer jacket. These measures allow less material to be used, while maintaining good mechanical properties. The porous or grid-like core structure is simultaneously used for transporting coolant. The base body is manufactured in particular by means of a 3D printing method.