Modular Metal Cutting Tool Part for Heat-Treated AM Front Sections
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Solution Overview
Problem
Traditional methods for producing metal cutting tool components are costly and cumbersome, especially when producing small numbers, as they require specific blanks and extensive machining, and heat treatment can affect dimensional tolerances of coupling parts.
Innovation Solution
A method involving the production of metal cutting tool components through connectable modules, where the front module is built using additive manufacturing and heat-treated separately from the rear module, allowing for reliable connection without strict tolerance requirements and enabling machining of surfaces only after module connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If heat treatment is applied to the tool body after additive manufacturing to provide mechanical strength and wear resistance, then the mechanical properties are improved, but the dimensional tolerances of the coupling part are affected
Solution Approach 1:
The tool body is divided into two separate modules: a coupling part and a cutting head. These modules are manufactured separately, with the coupling part produced by conventional machining and the cutting head by additive manufacturing. This segmentation allows each module to be optimized and treated independently, preventing heat treatment from affecting the coupling part's dimensional tolerances while still providing the cutting head with necessary mechanical properties.
Solution Approach 2:
The coupling part is extracted from the additive manufacturing process and produced separately by conventional machining. This extraction removes the coupling part from the heat treatment process, eliminating the adverse effect of heat treatment on dimensional tolerances while maintaining the benefits of additive manufacturing for the cutting head.
2Manufacturing precision
If conventional machining operations are used to machine the blank to final shape within desired tolerances, then the manufacturing precision is improved, but the production time and cost increase
Solution Approach 1:
The tool body is segmented into a coupling part requiring high precision (machined) and a cutting head where complex geometries benefit from additive manufacturing. This segmentation allows precision-critical features to be machined while other parts are additively manufactured, optimizing both precision and productivity.
Solution Approach 2:
Different manufacturing methods are applied to different parts of the tool body based on local requirements. The coupling part receives conventional machining for high precision, while the cutting head utilizes additive manufacturing for complex geometries, achieving local optimization of both precision and efficiency.
3Loss of substance
If a specific kind of blank is used for a specific kind of tool body to avoid removing more material than necessary, then the material utilization is improved, but the adaptability decreases
Solution Approach 1:
The tool body is divided into a coupling part and a cutting head that can be produced separately. The coupling part can be machined from standard blanks, while the cutting head can be additively manufactured with high material utilization. This segmentation provides flexibility in blank selection while maintaining efficient material usage.
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
This approach allows for cost-effective and time-efficient production of metal cutting tool components with maintained dimensional accuracy and mechanical strength, suitable for limited production runs and various applications, including cutting tools and machine tool components.
Implementation Method 1
building, using an additive manufacturing process, the main body on the build surface of the intermediate element
Implementation Method 2
separately heat treating the intermediate element with the built main body, wherein at least the main body is hardened
Data Source
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AI summary
The present disclosure relates to a method for producing a metal cutting tool component, comprising the steps of producing a front module (70), the front module (70) comprising a main body (57) and a front module interface (63) at a rear end. This step comprises the steps of providing an intermediate element (58), comprising providing the front module interface (63) at a rear end and a build surface (52) at a front end thereof, and building, using an additive manufacturing process, the main body (57) on the build surface (52) of the intermediate element (58). The method further comprises the steps providing a rear module (68) comprising providing a coupling part (66) at a rear end and a rear module interface (65) at a front end, after producing the front module and providing the rear module (68), mounting the front module (70) on the rear module (68) by immovably connecting the front module interface (63) and the rear module interface (65), after the front module (70) has been mounted on the rear module (68), machining at least one surface of the main body (57), and heat treating the intermediate element (58) with the built main body (57), wherein at least the main body (57) is hardened. The present disclosure also relates to a metal cutting tool component.