Polymer Machining Aid for Back Burr and Tool Fracture Suppression
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Solution Overview
Problem
Conventional wet processing methods for metal machining, such as those using machining oils, can lead to heat accumulation and tool wear, and may result in back burrs and tool cutting edge fractures, posing safety risks if residual oil deteriorates or loosens fasteners.
Innovation Solution
A material for assisting metal machining comprising a polymer compound with a melting point of 40° C. or more and a temperature at 5% weight loss of 275° C. or more, used in conjunction with a machining method that involves closely contacting the material with the metal surface before machining to suppress back burrs and tool edge fractures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If wet processing using machining oil is used to prevent heat accumulation, then heat release is improved, but residual oil may deteriorate or loosen fasteners leading to safety risks
Solution Approach 1:
The patent introduces a polymer compound as an intermediary substance between the machining tool and the workpiece. This polymer compound serves as a mediator that provides heat release benefits while avoiding the harmful effects of traditional machining oils, particularly the loosening of fasteners. The polymer compound decomposes at controlled temperatures to provide lubrication and heat management without leaving residual oil that could affect fastener integrity.
Solution Approach 2:
The patent changes the chemical and thermal parameters of the cooling/lubrication medium by using a polymer compound with specific decomposition characteristics. The polymer compound is selected to have a decomposition temperature range that allows it to provide lubrication during machining (below decomposition temperature) and then decompose completely after machining (above decomposition temperature), eliminating residual oil issues while maintaining heat release capabilities.
2Productivity
If drilling processing is performed on titanium alloy with high material strength, then machining capability is achieved, but tool wear increases remarkably
Solution Approach 1:
The polymer compound acts as an intermediary that reduces direct contact and friction between the machining tool and the titanium alloy workpiece. By introducing this intermediate layer, the tool experiences reduced wear while maintaining effective machining capability, as the polymer compound decomposes to provide lubrication during the machining process.
Solution Approach 2:
The patent converts the high friction and heat generation inherent in titanium alloy machining into a beneficial effect by using the polymer compound's decomposition. The decomposition process absorbs energy and provides lubrication, transforming the harmful friction into a controlled thermal and lubrication process that protects the tool while maintaining productivity.
3Strength
If heat conductivity is low in titanium alloy, then material strength is maintained, but heat release is insufficient causing back burr formation
Solution Approach 1:
The polymer compound serves as an external heat management intermediary that compensates for the titanium alloy's low intrinsic heat conductivity. By applying the polymer compound to the machining zone, heat is managed through the polymer's decomposition process rather than relying solely on the workpiece's thermal conduction, thereby preventing heat accumulation and back burr formation while preserving the material's strength properties.
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 proposed solution effectively suppresses back burrs and tool cutting edge fractures during metal machining, improving machining efficiency and safety by reducing heat accumulation and tool wear.
Implementation Method 1
a melting point is 40° C. or more... When the heat conductivity is low and heat release is insufficient, the temperature around a processed hole rises and the metal softens
Implementation Method 2
a temperature at 5% weight loss is 275° C. or more... frictional heat is generated between the rotating drill and the metal, locally increasing the temperature around a processed hole
Implementation Method 3
frictional heat is generated between the rotating drill and the metal... Using the material for assisting metal machining process... can suppress a back burr or fracture of a tool cutting edge
Data Source
AI summary
A material for assisting metal machining process, having a polymer compound, wherein a content of the polymer compound is 50% by mass or more based on the total amount of the material for assisting metal machining process, a melting point is 40° C. or more, and a temperature at 5% weight loss is 275° C. or more.