Dual-Channel Coolant Milling Tool for Insert Thermal Fatigue

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Solution Overview

Problem

Milling tools experience thermal fatigue due to high cutting insert temperatures, which reduce service life, especially when milling materials with low thermal conductivity and high yield stress values.

Innovation Solution

A milling tool design that includes a cutting insert, a holder, a fastener, and a shim, where the fastener forms a first channel to direct coolant to the insert top side and the shim forms a second channel to direct coolant to the clearance side, providing a permanent coolant jet independent of cutting or non-cutting cycles.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If a single coolant channel is used to cool the cutting insert, then the cooling effect during cutting is improved, but thermal fatigue increases due to temperature differences during thermal cycling

Engineering Contradiction:

Improvecutting insert temperatureVSAvoidthermal fatigue resistance

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The coolant supply system is segmented into two separate channels: a first coolant channel that supplies coolant to the top side of the cutting insert during cutting, and a second coolant channel that supplies coolant to the bottom side of the cutting insert. This segmentation allows independent cooling of different surfaces, reducing temperature differences and thermal stress during thermal cycling while maintaining effective cooling during cutting operations.

Inventive Principle:

Principle #1Segmentation

2Productivity

If coolant supply is only during cutting phase, then cooling efficiency is improved, but thermal expansion differences cause cracks during thermal cycling

Engineering Contradiction:

Improvecooling efficiencyVSAvoidinsert structural integrity

Core Design Contradiction:

ProductivityVSStability of the object's composition

Solution Approach 1:

The cooling action is made continuous by providing coolant supply to both the top and bottom sides of the cutting insert throughout the entire operational cycle, including both cutting and non-cutting phases. The first coolant channel operates during cutting to remove heat at the source, while the second coolant channel operates continuously to stabilize the bottom surface temperature, preventing thermal expansion differences and crack formation during thermal cycling.

Inventive Principle:

Principle #20Continuity of useful action

3Temperature

If coolant is directed only to the top side of the insert, then cutting zone cooling is improved, but thermal fatigue occurs due to uncooled bottom side

Engineering Contradiction:

Improvecutting zone temperatureVSAvoidinsert service life

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The coolant supply system is segmented into two separate channels: a first coolant channel that supplies coolant to the top side of the cutting insert, and a second coolant channel that supplies coolant to the bottom side. This segmentation allows targeted cooling of the cutting zone while simultaneously cooling the bottom surface to prevent thermal expansion differences, thereby extending insert service life.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different cooling strategies are applied to different locations of the cutting insert. The first coolant channel provides intensive cooling to the top side where the cutting edge generates the most heat, while the second coolant channel provides stabilization cooling to the bottom side to prevent thermal fatigue. This local differentiation of cooling quality optimizes both cutting performance and thermal fatigue resistance.

Inventive Principle:

Principle #3Local quality

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 dual coolant channels reduce temperature differences across the cutting insert, minimizing thermal fatigue and extending the service life of the cutting insert by maintaining a consistent coolant supply during both cutting and non-cutting phases.

Implementation Method 1

the first channel is configured to direct coolant towards the insert top side

Methodology Applied

Scientific EffectCooling: Cooling

Implementation Method 2

the second channel is configured to direct coolant towards the clearance side

Methodology Applied

Scientific EffectCooling: Cooling

Implementation Method 3

the differences in thermal expansion between different parts of the insert commonly initiate the formation and cause the successive propagation of cracks in the cutting insert

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentUS12337401B2Milling tool, use thereof and milling process

Publication Date: 2025.06.24 CERATIZIT LUXEMBOURG SARL

AI summary

A milling tool includes a cutting insert, a holder, a fastener and a shim. The fastener forms a first channel cooperatively with the cutting insert. The first channel is configured to direct coolant towards a top side of the insert. In order to better prevent thermal fatigue of the cutting insert under milling conditions, the shim includes a second channel configured to direct coolant towards a clearance side of the cutting insert. A method of using a milling tool and a milling process are also provided.