Tool Holder Coolant Nozzle Structure for High-Speed Cutting
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Solution Overview
Problem
Existing tool holders, particularly those for solid carbide tools, lack effective coolant capability due to manufacturing difficulties and centrifugal forces causing coolant to fan out radially, making it difficult to direct coolant to the cutting edge effectively, especially at high rotational speeds.
Innovation Solution
A tool holder with a fluid/coolant directing structure featuring nozzles configured to focus and direct coolant flow both radially inwardly and longitudinally distally, incorporating features like a ring of peripherally located nozzles, manifolds, and sinusoidally varying surfaces to manage coolant flow, connected to feeder channels via 3D printing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional tool holders are used without fluid directing structures, then the structure is simple and easy to manufacture, but coolant cannot be effectively delivered to the cutting edge at high rotational speeds due to centrifugal forces causing it to fan out radially
Solution Approach 1:
The fluid directing structure is segmented into multiple nozzles arranged in a ring configuration, with each nozzle independently directing coolant flow. This segmentation allows the coolant to be delivered through multiple pathways simultaneously, overcoming the centrifugal fan-out effect while maintaining a relatively simple overall structure that integrates with the tool holder.
Solution Approach 2:
The nozzles are oriented to direct coolant flow in both radial and axial dimensions simultaneously. By adding this multi-dimensional flow capability, the system overcomes the limitation of single-direction coolant delivery that fails at high speeds, without requiring a completely complex redesign of the holder structure.
2Productivity
If solid carbide tools are used, then cutting performance is improved, but manufacturing fluid/coolant holes in the tools becomes difficult and expensive
Solution Approach 1:
The tool holder acts as an intermediary structure that delivers coolant to the cutting tool through its fluid directing passages and nozzles. This eliminates the need to manufacture coolant holes directly in the solid carbide tool, maintaining high cutting performance while avoiding the manufacturing difficulties and costs associated with drilling precision holes in hard carbide material.
3Productivity
If high rotational speeds are used, then productivity is improved, but centrifugal forces cause coolant to fan out radially away from the tool, worsening coolant delivery
Solution Approach 1:
The nozzles are pre-configured with specific orientations and angles that counteract the centrifugal forces generated at high rotational speeds. By designing the nozzle geometry and arrangement in advance to oppose the expected centrifugal fan-out, the system maintains effective coolant delivery even at high productivity-enhancing rotational speeds.
Solution Approach 2:
The fluid directing structure is designed to dynamically adapt to rotational speeds through its nozzle configuration that directs coolant both radially inward and longitudinally distally. This dynamic flow pattern ensures coolant reaches the cutting edge regardless of the centrifugal forces generated at different rotational speeds, maintaining reliable coolant delivery across varying productivity conditions.
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
The solution effectively directs coolant to the cutting tool, enhancing coolant delivery at high rotational speeds and accommodating various tool sizes and shapes, improving coolant efficiency and tool performance.
Implementation Method 1
the high rotational speeds cause the fluid/coolant to 'fan out' radially away from the tool due to centrifugal force(s), that is, the inertial force caused by rotation of the tool directing the fluid/coolant away from the axis of rotation of the tool
Data Source
AI summary
A tool holder (e.g., shrink fit adapter) with fluid directing passages includes a shank and a fluid/coolant directing structure including one or more nozzles fluidically connected to feeder channels of the shank. The one or more nozzles each include an inner wall and an outer wall configured/shaped to direct fluid/coolant flow both radially inwardly and longitudinally distally and/or to variably modulate fluid/coolant flow around a nozzle outlet of or provided by the nozzle(s) in relation to a longitudinal central axis of the shank. The fluid/coolant directing structure incorporates one of more of: a ring of peripherally located nozzles having geometries/orientations configured to focus and direct thin sheets of fluid/coolant both radially inwardly and distally longitudinally; manifolds for directly feeding nozzle inlets of distally located nozzles; and a nozzle provided by approximately sinusoidally varying surfaces circumferentially disposed about a tool receiving recess of the tool holder for correspondingly variably modulating fluid/coolant flow direction through and exiting from the nozzle.