Machining Tool Coolant Channel Segmentation
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Solution Overview
Problem
Helical inner bores in machining tools increase flow resistance, reducing the amount of coolant and lubricant that can be supplied to the cutting area, leading to shorter tool lives and slower cutting speeds.
Innovation Solution
A tool design with a combination of straight and helical inner bores, where the straight section is used as a shank and the helical section as the cutting part, reducing flow resistance and allowing for a higher volume of coolant and lubricant to be conveyed, with a control element ensuring precise geometry and reproducibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If helical inner bores are used in the entire tool length, then the tool structure is simplified and manufacturing is easier, but the flow resistance increases and coolant delivery is reduced
Solution Approach 1:
The inner bore is divided into two distinct sections: a first section with a straight bore configuration and a second section with a helical bore configuration. This segmentation allows each section to be optimized for its specific function - the straight section minimizes flow resistance for coolant delivery, while the helical section provides the necessary tool geometry
Solution Approach 2:
Different sections of the inner bore are given different geometric properties - the first section has a straight configuration optimized for fluid flow, while the second section has a helical configuration optimized for structural requirements. This local differentiation resolves the contradiction by applying the appropriate bore type in the appropriate location
2Productivity
If helical inner bores are used throughout the tool, then chip removal is improved, but flow resistance increases and tool life decreases
Solution Approach 1:
The inner bore is segmented into a straight first section and a helical second section. The helical section is positioned to align with the chip evacuation path, providing effective chip removal, while the straight section maintains low flow resistance for coolant delivery, thereby extending tool life
Solution Approach 2:
The helical bore configuration is applied locally in the second section where chip removal is most critical, while the first section maintains a straight configuration optimized for coolant flow. This localized application of helical geometry achieves chip removal benefits without the penalty of increased flow resistance throughout the entire tool
3Quantity of substance
If straight inner bores are used throughout the tool, then coolant delivery is maximized, but the tool cannot maintain homogeneous structure
Solution Approach 1:
The tool structure is segmented into regions with different bore configurations - the straight first section provides excellent coolant delivery, while the helical second section maintains structural homogeneity and continuity with the rest of the tool geometry
Solution Approach 2:
The straight bore configuration is applied locally in the first section where coolant delivery is most important, while the helical configuration in the second section maintains the homogeneous structure required for tool integrity and performance
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 design extends tool life and increases cutting speeds by reducing flow resistance and ensuring consistent coolant and lubricant delivery, while maintaining a homogeneous structure and avoiding discontinuities that could reduce tool life.
Implementation Method 1
The helical inner bores lead to a higher flow resistance for the coolant and/or lubricant to be conveyed in the inner bores. For this reason, the amount of coolant and/or lubricant that can be supplied to the cutting area of the cutting tool per unit of time is reduced compared to internal bores guided in a straight line.
Data Source
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Figure 3
AI summary
The blank for the production of a chipping tool, comprises two or three internal bore (302, 303) for conducting fluid such as coolant and/or lubricants, and first, second and third sections along its longitudinal axis(304), where the internal bore is formed parallel to longitudinal axis of the blank in the first section. In the second section (308), the internal bore has a first spin with a first spin angle greater than zero. The blank is present through a continuous shaping extrusion process. The third section is arranged between the first and second section. The blank for the production of a chipping tool, comprises two or three internal bore (302, 303) for conducting fluid such as coolant and/or lubricants, and first, second and third sections along its longitudinal axis(304), where the internal bore is formed parallel to longitudinal axis of the blank in the first section. In the second section (308), the internal bore has a first spin with a first spin angle greater than zero. The blank is present through a continuous shaping extrusion process. The third section is arranged between the first and second section. In the third section, the internal bore limiting to the first section has no spin and the internal bore limiting to the second section has a second spin with a spin angle. The first and second spin angle is same. In the third section, the internal bore has a spin with a spin angle that changes continuously along the longitudinal axis of the blank. The first section comprises approximately half of the blank and/or the first spin angle has a value of 15, 20, 30 or 40 grades. The blank consists of hard metals or ceramics and has a homogeneous structure. Independent claims are included for: (1) a tool for chip-machining of workpiece; (2) a continuous shaping extrusion device for the production of blanks; and (3) a method for the production of blanks.