3D Printed Gear Cutting Tools With Capillaries for Direct Edge Lubrication
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Solution Overview
Problem
The manufacture and use of gear cutting tools with minimum quantity lubrication (MQL) capabilities are costly and time-consuming, requiring weeks or months for design and production before testing can begin, and often involve expensive external hardware.
Innovation Solution
A gear forming tool with a 3D printed gear cutting tool and capillaries, integrated with a tool holder and sleeves, allowing for efficient delivery of MQL, gas, or liquid lubrication directly to cutting edges through a network of fluid channels and capillaries, reducing the need for external hardware and accelerating the design and manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional gear cutting tools with MQL capability are manufactured, then lubrication capability is achieved, but manufacturing time and cost increase significantly
Solution Approach 1:
The patent utilizes capillary channels with porous-like structures integrated into the gear cutting tool body. These capillaries deliver lubricant directly to cutting edges through capillary action and pressure-driven flow, eliminating the need for complex external MQL hardware while achieving reliable lubrication during the gear cutting process
Solution Approach 2:
The invention merges the lubrication delivery system directly into the gear cutting tool structure by integrating capillary channels within the tool body. This combination eliminates separate external MQL hardware components and reduces manufacturing complexity, allowing simultaneous achievement of lubrication capability and reduced manufacturing time
2Reliability
If external hardware is used for MQL capability, then lubrication is achieved, but device complexity and cost increase
Solution Approach 1:
The invention merges the lubrication delivery system directly into the gear cutting tool structure by integrating capillary channels within the tool body. This combination eliminates separate external MQL hardware components and reduces manufacturing complexity, allowing simultaneous achievement of lubrication capability and reduced device complexity
Solution Approach 2:
The capillary channels are designed to deliver lubricant automatically through the tool structure using pressure-driven flow and capillary action. This self-service mechanism eliminates the need for complex external control systems and hardware, achieving reliable lubrication through the tool's own integrated structure
3Ease of manufacture
If conventional manufacturing methods are used, then tool structure is achieved, but manufacturing precision and complexity of capillary structures are limited
Solution Approach 1:
The patent utilizes additive manufacturing technology to create complex three-dimensional capillary channels within the gear cutting tool. This manufacturing method enables precise control of capillary geometry, diameter, and distribution patterns that cannot be achieved with conventional manufacturing methods, achieving both ease of manufacture and high manufacturing precision
Solution Approach 2:
The invention transitions from conventional two-dimensional or simple three-dimensional capillary designs to complex three-dimensional capillary networks enabled by additive manufacturing. This dimensional capability allows lubricant delivery paths to be optimized in all spatial dimensions, achieving superior manufacturing precision for capillary structures while maintaining ease of manufacture through digital design and additive fabrication
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 solution enables cost-effective and rapid production of gear cutting tools, allowing for lubrication of only the cutting edges in contact with the workpiece, improving machining efficiency and reducing lead form errors, while also enabling design and manufacture of complex capillary structures not feasible with traditional methods.
Implementation Method 1
a 3D printed gear cutting tool with a plurality of tool cutting edges and a plurality of capillaries... cutting fluid flows through the outer sleeve, the inner sleeve, the plurality of fluid channels of the tool holder, and the plurality of capillaries to the plurality of tool cutting edges
Data Source
AI summary
A gear forming tool includes an outer sleeve having an outer sleeve aperture and an inner sleeve having an inner sleeve aperture in fluid communication with the outer sleeve aperture, a tool holder disposed within the outer sleeve, and a 3D printed gear cutting tool with a plurality of tool cutting edges and a plurality of capillaries attached to the tool holder. The tool holder has a plurality of fluid channels configured to be in fluid communication with the inner sleeve aperture and the plurality of capillaries of the 3D printed gear cutting tool such that cutting fluid flows through the outer sleeve, the inner sleeve, the plurality of fluid channels of the tool holder, and the plurality of capillaries to the plurality of tool cutting edges.