Additively Printed Cutting Tools With Selective Edge Grinding
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Solution Overview
Problem
Current methods of manufacturing cutting tools using grinding limit design complexity due to difficulty and cost, and result in material waste.
Innovation Solution
Manufacturing cutting tools through additive printing followed by selective grinding of specific surfaces to form complex designs at near-net-shape, minimizing material loss and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If cutting tools are manufactured using traditional grinding methods, then the cutting edges can be precisely formed, but the design complexity is limited and material waste increases
Solution Approach 1:
The cutting tool body is additively manufactured in advance with complex internal geometries, coolant channels, and optimized structures before the final grinding step. This preliminary formation of complex features eliminates the need for difficult and costly post-processing of intricate shapes, while only the cutting edges require precision grinding.
Solution Approach 2:
The manufacturing process transitions from traditional subtractive grinding to additive manufacturing followed by selective grinding. This parameter change in the manufacturing approach enables complex designs that were previously impossible to grind, while maintaining precision cutting edges through targeted grinding of only the necessary surfaces.
2Manufacturing precision
If cutting tools are manufactured using traditional grinding methods, then the cutting edges can be precisely formed, but material waste increases
Solution Approach 1:
The tool body is additively manufactured to near-net-shape with precise geometry before final grinding. This preliminary precision formation reduces the amount of material that needs to be removed during grinding, significantly reducing material waste while maintaining cutting edge precision.
Solution Approach 2:
The process shifts from entirely subtractive manufacturing (grinding) to a hybrid approach combining additive manufacturing with selective grinding. This parameter change enables near-net-shape production, minimizing material removal and waste while preserving the ability to create precise cutting edges.
3Ease of manufacture
If cutting tools are manufactured using traditional grinding methods, then the manufacturing process is simple, but design complexity is limited
Solution Approach 1:
Complex design features are preliminarily created through additive manufacturing, which handles geometric complexity naturally. This separates the creation of complex geometry from the finishing process, allowing simple automated additive processes to produce complex shapes that would require intricate multi-step grinding operations.
Solution Approach 2:
The manufacturing methodology changes from traditional grinding to additive manufacturing with selective grinding. This parameter change enables complex designs by using additive processes that can naturally form intricate geometries, while the simplicity of the overall process is maintained through automation and reduced post-processing requirements.
4Device complexity
If complex cutting tools are manufactured using traditional methods, then the manufacturing cost increases, but design complexity can be achieved
Solution Approach 1:
Complex features are preliminarily formed through additive manufacturing in a single integrated process, eliminating the need for multiple expensive machining operations. This preliminary formation of complex geometries, internal channels, and optimized structures reduces manufacturing steps and associated costs while maintaining design complexity.
Solution Approach 2:
The manufacturing approach transitions to additive manufacturing with selective grinding, which reduces overall manufacturing cost despite enabling complex designs. The additive process is more cost-effective for complex geometries than traditional multi-step machining, and selective grinding minimizes additional costs by grinding only the necessary surfaces.
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 the production of complex cutting tools with precise cutting edges and optimized chip flow, reducing material waste and manufacturing costs while maintaining tool strength.
Implementation Method 1
the cutting tool may be additively printed
Implementation Method 2
a rake face and a flank face of the cutting tool may be grinded
Data Source
AI summary
A method of manufacturing a cutting tool is disclosed. The cutting tool may be additively printed. This may allow the formation of a complex design with varying surfaces of the cutting tool in differing configurations and orientations. Then, a rake face and a flank face of the cutting tool may be grinded to form a cutting surface.