Dual-Channel Milling Insert Cooling for Thermal Fatigue Reduction
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Solution Overview
Problem
Milling tools experience thermal fatigue due to thermal cycling, leading to reduced cutting insert service life, especially when machining materials with low thermal conductivity and high yield stress values, as existing coolant supply methods are insufficient in managing thermal expansion differences.
Innovation Solution
A milling tool design featuring a cutting insert, holder, and shim, where the fastener forms a first channel for coolant to the insert top side and a second channel for the clearance side, providing continuous coolant supply independent of cutting action, reducing temperature amplitude and thermal deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single coolant channel is used to cool the cutting insert, then the cooling structure is simple, but the thermal expansion differences during milling cause thermal fatigue and reduced service life
Solution Approach 1:
The coolant supply system is segmented into two separate channels: a first coolant channel that supplies coolant to the top surface of the cutting insert, and a second coolant channel that supplies coolant to the bottom surface of the cutting insert. This segmentation allows independent cooling of different surfaces, effectively managing thermal expansion differences and preventing thermal fatigue, thereby extending cutting insert service life.
2Device complexity
If coolant is supplied only during cutting phase, then the cooling system is simple, but thermal cycling causes thermal fatigue and insert failure
Solution Approach 1:
The coolant supply system operates continuously throughout the entire milling cycle, including both cutting and non-cutting phases. The first coolant channel maintains continuous cooling of the top surface, while the second coolant channel continuously cools the bottom surface. This continuous cooling action eliminates thermal cycling and prevents thermal fatigue, ensuring reliable operation throughout the complete milling cycle.
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 continuous coolant supply through both channels significantly reduces thermal fatigue, extending the cutting insert's service life by maintaining consistent cooling during both cutting and non-cutting phases of the milling process.
Implementation Method 1
the first channel is configured to direct coolant towards the insert top side
Implementation Method 2
the shim comprises a second channel configured to direct coolant towards the clearance side
Implementation Method 3
the first channel is in fluid communication with a base channel of the holder
Data Source
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AI summary
In order to provide for a milling tool (1, 1') which comprises a cutting insert (2, 2'), a holder (3), a fastener (4) and a shim (5, 5'), wherein the fastener (4) forms cooperatively with the cutting insert (2, 2') a first channel (100) and the first channel (100) is configured to direct coolant towards the insert top side (21, 21'), such that thermal fatigue of the cutting insert (2, 2') is better prevented under milling conditions, it is suggested that the shim (5, 5') comprises a second channel (200) configured to direct coolant towards a clearance side (27) of the cutting insert (2, 2').