Additive Tool Head Cooling Channels for Turning Inserts
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Solution Overview
Problem
Existing turning tools face limitations in optimizing the cooling effect at the machining point due to the scatter of coolant jets and the high cost of producing branched coolant channel systems.
Innovation Solution
The method involves additive manufacturing to create a layered tool head with complex coolant channel systems, including bends and optimized outlet openings, which ensures targeted coolant delivery to the machining point, using techniques like laser sintering or electron beam melting, and forming the tool head and outlet openings directly in the layered structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional methods are used to create branched coolant channel systems, then manufacturing precision and coolant delivery can be achieved, but device complexity and manufacturing cost increase significantly
Solution Approach 1:
The patent changes the manufacturing method from conventional subtractive or formative processes to additive manufacturing (3D printing). This parameter change enables the direct creation of complex branched coolant channel systems with precise geometry, including optimized outlet openings positioned exactly where needed, without the complexity and cost associated with conventional manufacturing methods.
Solution Approach 2:
The patent replaces complex mechanical manufacturing processes (milling, drilling, tapping of complex channels) with an additive manufacturing process. This substitution allows for the direct deposition of material to form complex coolant channel geometries that would be difficult or impossible to create with traditional mechanical methods, thereby reducing device complexity while maintaining precision.
2Temperature
If outlet openings are positioned optimally on the tool head, then cooling efficiency at the machining point improves, but manufacturing complexity increases
Solution Approach 1:
The patent changes the manufacturing approach to additive manufacturing, which allows outlet openings to be positioned optimally at any location on the tool head surface. The digital modeling capability of 3D printing enables precise positioning of multiple outlet openings to direct coolant jets exactly at the machining point, maximizing cooling efficiency without the manufacturing difficulties associated with conventional methods.
Solution Approach 2:
The patent utilizes the third dimension provided by additive manufacturing to position outlet openings at optimal locations on the tool head surface. The layer-by-layer construction allows for the creation of outlet openings at various heights and angles, enabling three-dimensional optimization of coolant delivery paths to the machining point, which would be difficult to achieve with conventional two-dimensional manufacturing approaches.
3Adaptability or versatility
If complex branched coolant channel systems are manufactured using conventional methods, then coolant can be delivered to various areas, but production cost and time increase
Solution Approach 1:
The patent changes the manufacturing process parameter from conventional batch manufacturing to additive manufacturing. This enables complex branched coolant channel systems to be manufactured in a single integrated process rather than through multiple sequential operations (drilling, tapping, assembling). The digital design can be directly translated into the final part, significantly reducing production time while maintaining the adaptability to deliver coolant to multiple areas through optimized channel routing.
Solution Approach 2:
The patent merges multiple manufacturing operations into a single additive manufacturing process. The tool head with its complex branched coolant channel system, outlet openings, and mounting features are all created in one continuous build process, eliminating the need for separate drilling, tapping, and assembly operations. This consolidation dramatically improves productivity while preserving the versatile coolant distribution capability.
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 approach enhances the cooling efficiency at the machining point by providing optimal coolant supply and reduces production costs through the use of additive manufacturing techniques, allowing for precise coolant distribution and complex channel routing.
Implementation Method 1
The tool head is most conveniently manufactured using laser sintering
Implementation Method 2
Alternatively, it would also be possible to use laser beam melting or electron beam melting
Implementation Method 3
a tool head coolant channel system connected to the base body coolant channel with at least one tool head coolant channel
Data Source
Figure 1~2
Figure 3
Figure 4~6
AI summary
The invention relates to a method for manufacturing turning tools (11) for machining workpieces by turning, wherein the turning tools (11), each having a longitudinal axis (12), each have a base body (13) equipped with at least one base body coolant channel (16), which has two oppositely oriented end faces (14a, b), wherein a tool head (17) is arranged on one of the end faces (14a), which has a tool head coolant channel system (18) connected to the base body coolant channel (16) with at least one tool head coolant channel (19) and a cutting insert seat (21) equipped with at least one seating surface (20a-c) for receiving a cutting insert (22), the method proceeds with the following steps: - providing at least one base body blank (40) equipped with the base body coolant channel (18),- Layer-by-layer construction of the tool head (17) on the associated end face (14a) of the base body blank (40) by additive manufacturing, wherein both the tool head coolant channel system (18) in a manner communicating with the base body coolant channel (16) and the cutting insert seat (21) are formed directly.