Rotating Cutting Tool Cooling With Closed-Loop Internal Channels
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Solution Overview
Problem
Existing coolant delivery systems for rotating cutting tools are inefficient, leading to high energy consumption, significant coolant usage, and health risks due to hazardous waste, while external coolant application methods are costly and ineffective in maintaining tool temperature control for high material removal rates.
Innovation Solution
A closed circulation loop system with internal cooling channels and a refrigerant medium, such as ammonia or CO2, that cycles between liquid and vapor states to deliver a two-phase cooling medium directly to the cutting edges of rotating cutting tools, recycling and reconditioning the coolant for efficient thermal energy transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If external coolant delivery systems are used, then cooling effect is achieved, but energy consumption increases significantly
Solution Approach 1:
The patent extracts the coolant delivery function from the external system and integrates it directly into the rotating tool. Internal cooling channels are built into the tool body, allowing coolant to be delivered directly at the cutting zone without requiring external delivery mechanisms, thereby reducing energy consumption while maintaining effective cooling.
Solution Approach 2:
The cooling channels are nested within the tool structure itself. The patent describes cooling channels formed within the tool body that guide coolant from the tool's interior to the cutting edges, creating a nested configuration where the cooling system is embedded within the tool rather than being external.
2Temperature
If external coolant delivery systems are used, then cooling effect is achieved, but coolant usage increases significantly
Solution Approach 1:
The patent extracts the coolant delivery function from the external system and integrates it directly into the rotating tool. Internal cooling channels are built into the tool body, allowing coolant to be delivered directly at the cutting zone without requiring external delivery mechanisms, thereby reducing energy consumption while maintaining effective cooling.
Solution Approach 2:
The patent applies cooling locally at the cutting zone through internal channels that deliver coolant directly to the cutting edges. This localized delivery method ensures coolant is applied precisely where needed rather than being dispersed externally, reducing overall coolant consumption while maintaining effective cooling at the critical temperature zones.
3Temperature
If external coolant delivery systems are used, then cooling effect is achieved, but health risks and capital investment increase
Solution Approach 1:
The patent extracts the coolant delivery function from the external system and integrates it directly into the rotating tool. Internal cooling channels are built into the tool body, allowing coolant to be delivered directly at the cutting zone without requiring external delivery mechanisms, thereby reducing energy consumption while maintaining effective cooling.
Solution Approach 2:
The patent applies cooling locally at the cutting zone through internal channels that deliver coolant directly to the cutting edges. This localized delivery method ensures coolant is applied precisely where needed rather than being dispersed externally, reducing overall coolant consumption while maintaining effective cooling at the critical temperature zones.
4Productivity
If cutting speed is increased to achieve higher material removal rate, then productivity improves, but cutting temperature increases quickly
Solution Approach 1:
The patent implements preliminary cooling action by delivering coolant to the cutting zone before and during the cutting process through internal channels. The coolant is pre-positioned within the tool structure to meet the thermal demands at the cutting edges, enabling the tool to sustain higher cutting speeds and material removal rates without excessive temperature increase.
Solution Approach 2:
The patent ensures continuous cooling action through internal channels that deliver coolant consistently to the cutting zone throughout the cutting process. This continuous cooling enables sustained high-speed operation and maintains optimal cutting temperatures even during prolonged high-productivity machining operations.
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 reduces energy consumption by up to 50% and minimizes coolant usage and waste, enhancing tool life and productivity by maintaining optimal cutting temperatures, thus reducing capital investment and improving machining efficiency and safety.
Implementation Method 1
A closed circulation loop system with internal cooling channels and a refrigerant medium, such as ammonia or CO2, that cycles between liquid and vapor states to deliver a two-phase cooling medium directly to the cutting edges
Implementation Method 2
recycling and reconditioning the coolant for efficient thermal energy transfer
Data Source
Figure 1
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Figure 3
AI summary
A rotary tool (46) includes a shank (48), cutting portion (50), coolant inlet (66), coolant outlet (68), and channel system. The cutting portion (50) is connected to and extends from the shank (48). The cutting portion (50) includes a cutting edge (54). The coolant inlet (66) and the coolant outlet (68) are disposed in the shank (48). The channel system is contained in the rotary tool (46) and is a closed circulation loop system such that the coolant is contained within the channel system as the coolant is circulated within the rotary tool (46). The channel system includes a delivery path (60) and a return path (62). The delivery path is fluidly connected to the coolant inlet (66) and includes a shape corresponding to a shape of the cutting edge (54). The return path (62) is fluidly connected to the coolant outlet (68) and to the delivery path (60) at a location in the cutting portion (50) of the rotary tool (46).