Milling Insert Coolant Delivery via Segmented Diverter
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Solution Overview
Problem
In milling operations, excessive heat at the insert-chip interface reduces tool life due to increased wear and breakage, and chip sticking to the insert can lead to re-cutting and decreased efficiency.
Innovation Solution
A milling cutter and insert design with enhanced coolant delivery systems, including coolant passages and diverter structures, that direct coolant flow to the cutting edge and chip interface to reduce heat, prevent chip sticking, and facilitate chip evacuation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If coolant delivery to the insert-chip interface is enhanced, then heat at the insert-chip interface is reduced and tool life is extended, but device complexity increases due to additional coolant passages and diverter structures
Solution Approach 1:
The coolant delivery system is segmented into multiple independent passages within the insert body, with each passage serving a specific cutting edge or region. The diverter structure is also segmented into multiple positions that can be selectively activated. This segmentation allows the system to provide targeted coolant delivery to specific areas needing cooling without requiring a completely complex system architecture.
Solution Approach 2:
The coolant passages are pre-formed within the insert body during manufacturing, and the diverter structure is pre-positioned in the holder. This preliminary preparation of coolant pathways and components eliminates the need for complex assembly procedures or operational adjustments, reducing the perceived complexity while maintaining effective coolant delivery to extend tool life.
2Temperature
If coolant delivery system with multiple passages and diverters is implemented, then cooling effectiveness is improved, but manufacturing complexity increases
Solution Approach 1:
The manufacturing process is segmented into separate steps: insert body fabrication with embedded passages, holder manufacturing with diverter integration, and final assembly. This segmentation allows each component to be manufactured using optimized processes for its specific requirements, reducing overall manufacturing complexity while achieving effective temperature control through the multi-passages coolant system.
3Productivity
If chip evacuation is improved through coolant flow, then re-cutting is prevented and productivity increases, but device complexity increases due to additional coolant delivery components
Solution Approach 1:
The coolant delivery system is designed with multi-functionality: the same coolant passages and diverter structure simultaneously provide cooling to reduce temperatures and generate flow to evacuate chips from the cutting zone. This universal design prevents chip re-cutting and maintains high productivity without requiring separate dedicated systems for cooling and chip evacuation, thereby avoiding additional device complexity.
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 extends tool life, reduces wear, prevents chip re-cutting, and enhances operational efficiency by maintaining lower temperatures and better lubrication at the insert-chip interface.
Implementation Method 1
coolant flows through a passage in the insert body and over a selected one of the cutting edges
Implementation Method 2
heat is generated at the interface between the cutting insert and the location where the chip is removed from the workpiece
Implementation Method 3
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 assembly for use in chipforming and material removal wherein the cutting insert assembly is received in a pocket of a cutter body wherein coolant can flow out of a pocket opening contained in the pocket. The cutting insert assembly includes a cutting insert body that presents at least two discrete cutting locations. The cutting insert body contains a coolant entry passage aligned with the pocket opening for coolant to flow through the coolant entry passage. The cutting insert body has a rake surface that contains at least two of the discrete depressions wherein each one of the discrete depressions corresponds to one of the cutting locations. Each one of the discrete depressions extends toward its corresponding cutting location. The assembly includes a diverter that is positioned adjacent to the cutting insert body wherein the diverter has a receiving opening aligned with the coolant entry passage to receive coolant through the coolant entry passage. The diverter includes a coolant trough in communication with the receiving opening wherein the coolant trough is aligned toward a selected one of the cutting locations whereby the coolant trough and the discrete depression corresponding to the selected cutting location define a conduit for the flow of coolant toward the selected cutting location.