Movable Extrusion Die for Cutting Tool Blanks With Integrated Flutes
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Solution Overview
Problem
The production of cutting tools involves elaborate post-processing of green bodies to introduce flutes and cutting edge geometries, which is time-consuming and material-intensive, and often results in solid tool shanks that require additional processing to create cooling channels, leading to inefficiencies and increased costs.
Innovation Solution
A method using an extruder with a movable mold element to create green bodies with varying geometries in a continuous extrusion process, allowing for the formation of hollow shafts, cooling channels, and flutes, reducing the need for extensive post-processing and material usage by integrating these features during the extrusion process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional extrusion method with fixed die is used, then production process is simple, but extensive post-processing is required to create flutes, cooling channels, and complex geometries
Solution Approach 1:
The patent applies the dynamics principle by making the die movable instead of fixed. The die can be moved along the extrusion axis during the extrusion process, allowing the geometry of the green body to change continuously along its length. This enables complex features like flutes, cooling channels, and varying cross-sections to be formed directly during extrusion, eliminating the need for extensive post-processing operations.
2Quantity of substance
If traditional extrusion method is used, then material usage is efficient, but solid tool shanks require additional material removal for cooling channels
Solution Approach 1:
The patent applies the preliminary action principle by forming cooling channels, flutes, and other geometric features directly during the extrusion process itself, before the green body is fully formed and before any post-processing occurs. The movable die creates these features as integral parts of the green body geometry, eliminating the need for subsequent material removal operations and maximizing material efficiency.
3Device complexity
If fixed die extrusion is used, then device complexity is low, but geometric complexity of cutting tools is limited
Solution Approach 1:
By making the die movable along the extrusion axis, the patent transforms a static forming tool into a dynamic one. This allows the die geometry to vary continuously or in steps during the extrusion process, enabling the production of green bodies with complex, varying geometries including flutes, cooling channels, and non-uniform cross-sections, while adding only one degree of freedom to the device.
4Manufacturing precision
If elaborate post-processing is applied, then cutting tool precision is improved, but production cost increases
Solution Approach 1:
The patent applies preliminary action by forming the final complex geometry of the cutting tool directly during the extrusion process itself, rather than starting with a simple cylindrical green body and adding features through post-processing. The movable die creates flutes, cooling channels, and varying cross-sections as integral parts of the green body, reducing the need for elaborate subsequent machining operations and associated equipment.
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 minimizes the need for extensive post-processing, saves material, and allows for more efficient cooling channel design, reducing production costs and time while enhancing the geometric complexity of cutting tools.
Implementation Method 1
a green body extending in the direction of the extrusion axis is produced from extrusion material by an extruder, which has an extrusion channel extending along an extrusion axis
Data Source
AI summary
The invention relates to a method for producing a blank, in particular a blank for the production of a cutting tool, wherein a green body extending in the direction of the extrusion axis is produced from extrusion material by means of an extruder which has an extrusion channel extending along an extrusion axis; wherein the extrusion channel together with a movable mold element forms a die of the extruder; and wherein the mold element is moved relative to the extrusion channel and within said extrusion channel during the extrusion of the green body, whereby the shaping geometry of the die is changed so that the completely extruded green body hereby has a first functional segment and a second functional segment adjacent thereto in the direction of the extrusion axis (4); wherein the two functional segments differ with regard to their geometries impressed by the die.