Micro-Channel Cutting Insert for Chip-Tool Contact Cooling
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Solution Overview
Problem
Existing cutting tools face limited cooling impact during finishing operations due to the inability of coolant to access the intimate contact zone between the chip and rake surface, leading to increased friction forces.
Innovation Solution
A cutting insert with a grid pattern of micro channels on the rake face adjacent to the cutting edge, which can be filled with a cooling fluid to form a cushion for the chip, reducing friction and improving cooling, combined with internal cooling channels connected to a cooling medium source.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If coolant is delivered through tool holder or coolant nozzles at high pressure, then chip control is enhanced, but cooling impact during finishing operations is limited due to inability to access the contact zone between chip and rake surface
Solution Approach 1:
The rake face is segmented into multiple micro channels arranged in a grid pattern, allowing coolant to be delivered to multiple discrete locations simultaneously. This segmentation enables the coolant to access the contact zone between chip and rake surface at multiple points, overcoming the limitation of conventional single-point coolant delivery and enhancing cooling impact during finishing operations
Solution Approach 2:
The invention transitions from conventional external coolant delivery (tool holder or nozzle) to internal coolant delivery embedded within the rake face structure. By integrating micro channels directly into the rake face, the system moves the coolant delivery from a external dimension to an internal dimension, enabling direct access to the contact zone that was previously inaccessible
2Temperature
If micro channels are made closer to the cutting edge, then cooling efficiency is improved, but mechanical strength of the cutting edge is negatively affected
Solution Approach 1:
The micro channels are positioned at an optimized distance from the cutting edge, creating a local quality distribution where the rake face has different structural characteristics in different regions. The area near the cutting edge maintains higher mechanical strength, while the area further away contains the micro channels for efficient cooling, achieving local optimization of both strength and cooling performance
3Temperature
If the distance between neighboring micro channels is reduced, then cooling coverage is improved, but mechanical strength of portions between micro channels is compromised
Solution Approach 1:
The spacing between neighboring micro channels is optimized to balance cooling coverage and mechanical strength. By carefully selecting the distance parameter between channels, the system achieves sufficient cooling coverage across the rake face while maintaining adequate mechanical strength in the portions between channels to support cutting loads
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
Significantly reduces cutting force and specific energy by minimizing chip-tool contact area, decreasing friction coefficient, and enhancing chip fragmentation and evacuation, while reducing adiabatic shearing effects.
Implementation Method 1
enhancing the cooling effect of a cutting insert and at the same time lubricate the tool-chip contact
Implementation Method 2
lubricate the tool-chip contact in order to reduce friction forces between the cutting insert and the chip
Data Source
AI summary
A cutting insert for a cutting tool, comprising a body (1) having: a cutting edge (2), a rake face (3), and micro channels (4, 5), provided on said rake face (3) adjacent the cutting edge (2). The micro channels (4, 5) define a grid pattern (6) of micro channels (4, 5) that intersect each other in a region of the rake face (3) where contact between a chip and the rake face (3) is assumed to occur during cutting with the cutting insert.