Milling Insert Internal Coolant Channels
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In milling operations, excessive heat at the insert-chip interface reduces tool life, leads to premature breakage and wear, and causes chip sticking, which can result in re-cutting, due to inadequate coolant delivery.
Innovation Solution
A milling cutter and insert design with internal channels and diverter plates that efficiently deliver coolant to the cutting edge, providing effective lubrication and heat reduction by directing coolant flow proximate to the cutting location, thereby preventing chip accumulation and re-cutting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional coolant delivery methods are used, then coolant is supplied to the cutting insert, but heat reduction at the insert-chip interface is insufficient
Solution Approach 1:
The patent introduces internal channels and diverter plates as intermediary structures within the cutting insert to mediate coolant delivery. The coolant flows through these internal passages and is redirected by diverter plates to achieve precise delivery at the insert-chip interface, effectively reducing heat where conventional methods fail
Solution Approach 2:
The patent utilizes hydraulic principles by designing internal fluid passages that guide coolant flow through the cutting insert. The coolant is delivered under pressure through strategically positioned outlets and diverter plates to maximize cooling effectiveness at the insert-chip interface
2Reliability
If coolant delivery is improved to reduce heat, then tool life increases, but device complexity increases due to internal channels and diverter plates
Solution Approach 1:
The patent merges the coolant delivery function with the cutting insert structure itself by integrating internal channels and diverter plates into the insert body. This combination eliminates the need for separate external cooling systems and reduces overall system complexity while maintaining enhanced cooling performance
Solution Approach 2:
The cutting insert is designed with multi-functionality by incorporating coolant channels and diverter plates that serve both structural and thermal management functions. The same insert structure that performs cutting also manages coolant delivery, reducing the need for additional components
3Object-generated harmful factors
If coolant flow is increased to prevent chip sticking, then chip evacuation improves, but coolant consumption increases
Solution Approach 1:
The patent applies local quality by delivering coolant precisely where needed at the insert-chip interface through targeted outlets and diverter plates. This localized delivery prevents chip sticking at the critical interface without requiring high volumes of coolant, as cooling is concentrated where heat generation occurs
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 improved coolant delivery system enhances tool life, reduces heat buildup, prevents chip sticking, and ensures efficient chip evacuation, leading to increased production efficiency and reduced operating costs.
Implementation Method 1
The internal channel has an inlet to receive coolant and an outlet to exit coolant. The outlet is proximate to the cutting location, and the inlet is radial inward of the outlet.
Implementation Method 2
there is enhanced delivery of coolant adjacent the interface between the milling insert and the workpiece (i.e., the insert-chip interface) to diminish excessive heat at the insert-chip interface
Implementation Method 3
The consequence of enhanced lubrication at the insert-chip interface is a decrease in the tendency of the chip to stick to the cutting insert.
Data Source
AI summary
A cutting insert for use in chipforming and material removal from a workpiece wherein coolant is supplied to the cutting insert from a coolant source. The cutting insert includes at least one discrete cutting location and at least one distinct internal channel that corresponds to the cutting location. The internal channel has an inlet to receive coolant and an outlet to exit coolant. The outlet is proximate to the cutting location, and the inlet is radial inward of the outlet.