Sintered Tool Head Assembly With Integrated Coolant Channels
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Solution Overview
Problem
Existing methods for manufacturing tool heads of rotary cutting tools require expensive post-sintering machining for coolant channels, limiting the complexity and efficiency of coolant supply to cutting edges.
Innovation Solution
A method that forms coolant channels in the interface between preformed parts using grooves, allowing for non-linear, complex shapes without sharp transitions, enabling efficient coolant supply to all cutting edges without post-sintering machining, using techniques like powder injection moulding or multiaxial pressing, and sintering to create a cost-effective and performance-enhanced tool head.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If coolant channels are formed by post-sintering machining (e.g., EDM), then manufacturing precision of coolant channels can be achieved, but production cost increases significantly
Solution Approach 1:
The patent forms coolant channels as grooves in the green body before sintering, rather than machining them after sintering. This preliminary formation of channels using molding techniques avoids expensive post-sintering machining operations like EDM, thereby reducing production costs while maintaining adequate channel precision for coolant flow
Solution Approach 2:
The patent replaces mechanical post-sintering machining (EDM) with a molding-based approach where channels are formed as grooves in the green body during the forming stage. This substitution eliminates the need for expensive mechanical machining operations after sintering, reducing both cost and production time
2Reliability
If coolant channels have complex non-linear shapes, then coolant distribution to all cutting edges is improved, but manufacturing complexity increases
Solution Approach 1:
The patent forms complex non-linear coolant channels as grooves in the green body before sintering, utilizing molding techniques that can create complex geometries directly. This preliminary formation allows complex channel shapes to be achieved without proportionally increasing manufacturing complexity, as the grooves are formed during the molding stage rather than requiring complex post-processing
Solution Approach 2:
The patent creates three-dimensional non-linear coolant channels by forming grooves in the green body that extend through multiple dimensions. The channels can curve and change direction in complex ways, allowing coolant to reach all cutting edges effectively. The groove formation process naturally accommodates these complex spatial configurations
3Ease of manufacture
If coolant channels have sharp transitions or edges, then manufacturing is simpler, but pressure drops occur reducing tool head performance
Solution Approach 1:
The patent forms coolant channels with curved walls without sharp transitions or edges by creating grooves in the green body that naturally produce smooth contours. The groove formation process allows for curved channel walls that eliminate sharp edges, thereby preventing pressure drops in coolant flow while maintaining ease of manufacture through the molding process
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 method reduces production costs and improves tool head performance by eliminating the need for expensive machining and ensuring effective coolant distribution to all cutting edges, enhancing the tool's efficiency and dynamic properties.
Implementation Method 1
Joining the assembled parts in a sintering operation to form the tool head
Data Source
Figure 1~5
Figure 6~7
Figure 8~10
AI summary
A method for manufacturing a tool head, comprising: - forming a first and a second part (4, 4') from a powder composition, wherein the first and the second parts comprise corresponding joining surfaces (5), and wherein the parts comprise outer surface portions (6, 6') configured to form portions of a peripheral envelope surface of the tool head, - forming corresponding grooves (15) in the corresponding joining surfaces, - assembling the parts into a shape of a tool head by bringing the joining surfaces into contact to form an interface, so that each pair of corresponding grooves forms a channel extending in the interface, the channel having an inlet opening in a rear end of the tool head and an outlet opening in a front end or in the peripheral envelope surface of the tool head, - joining the assembled parts in a sintering operation to form the tool head.