Modular Metal Cutting Tool Part for Heat-Treated Precision
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Solution Overview
Problem
Traditional methods for producing metal cutting tool components are time-consuming and costly, especially when producing small numbers, and heat treatment can affect dimensional tolerances.
Innovation Solution
A method involving additive manufacturing of a metal cutting tool component as two connectable modules, where the front module is built and hardened separately from the rear module, allowing for machining after connection and avoiding heat treatment of the rear module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the tool body is produced as a single integrated component using additive manufacturing, then the production process is simplified, but heat treatment affects dimensional tolerances of the coupling part
Solution Approach 1:
The tool body is divided into two separate modules: a coupling part (rear module) and a cutting head (front module). The coupling part is produced by conventional machining while the cutting head is produced by additive manufacturing. This segmentation allows each module to be manufactured using the most appropriate process for its specific requirements, avoiding heat treatment of the coupling part while maintaining production efficiency.
Solution Approach 2:
Different manufacturing approaches are applied to different parts of the tool body based on their specific requirements. The coupling part requires high dimensional accuracy and is produced by conventional machining, while the cutting head requires high strength and is produced by additive manufacturing with heat treatment. This local quality approach optimizes the manufacturing process for each specific region.
2Manufacturing precision
If conventional machining is used to produce the tool body, then dimensional tolerances are maintained, but production time and cost increase significantly
Solution Approach 1:
The tool body is segmented into a coupling part produced by conventional machining (maintaining tolerances) and a cutting head produced by additive manufacturing (increasing productivity). This allows the majority of the tool body to be manufactured quickly using additive processes while only the critical coupling interface is machined to precise tolerances.
Solution Approach 2:
The manufacturing approach changes from uniform conventional machining to a hybrid process combining additive manufacturing and selective machining. This parameter change in the manufacturing process enables both high productivity through additive manufacturing and high precision through selective machining of only the necessary surfaces.
3Productivity
If additive manufacturing is used for the entire tool body, then production cost and time are reduced, but heat treatment distorts the coupling part dimensions
Solution Approach 1:
The tool body is divided into a coupling part (produced by conventional machining without heat treatment) and a cutting head (produced by additive manufacturing with heat treatment). This segmentation isolates the heat treatment process to only the cutting head, preserving the dimensional accuracy of the coupling part while maintaining the productivity benefits of additive manufacturing.
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 dimensional distortion while allowing the cutting head to be produced efficiently using additive manufacturing and heat treatment.
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
Enables cost-effective production of metal cutting tool components with precise tolerances and alignment, even when produced in limited quantities, by separating the modules to avoid heat treatment effects on dimensional accuracy.
Implementation Method 1
building, using an additive manufacturing process, the main body on the build surface of the intermediate element
Implementation Method 2
heat treating the intermediate element with the built main body, wherein at least the main body is hardened
Data Source
AI summary
A method for producing a metal cutting tool component and a metal cutting tool component. The method includes the step of producing a front module having a main body and a front module interface at a rear end thereof, providing an intermediate element and building, using an additive manufacturing process, the main body on the build surface of the intermediate element. Further, a rear module including a coupling part at a rear end thereof and a rear module interface at a front end thereof is provided, and mounting the front module on the rear module by immovably connecting the front module and rear module interfaces, after the front module has been mounted on the rear module, machining at least one surface of the main body, and heat treating the intermediate element with the built main body, wherein at least the main body is hardened.