Milling cutter with lubrication conduits

A lubricant distribution device configured to be coupled to a rotating cutting tool having a plurality of circumferentially spaced cutting surfaces comprises a main body having a manifold conduit extending along a central rotational axis of the main body and a plurality of lubricant distributing conduits formed in the main body and extending radially outwardly from the manifold conduit. Each of the lubricant distributing conduits is configured to convey a lubricant therethrough and includes an inlet fluidly coupling each of the lubricant distributing conduits to the manifold conduit and an outlet disposed adjacent a corresponding one of the circumferentially spaced cutting surfaces of the cutting tool.

FIELD OF THE INVENTION

The present invention relates to a minimum quantity lubrication cutting tool, and more specifically to an MQL cutting tool having fluid conduits for delivering a lubricating aerosol to each cutting surface of the cutting tool.

BACKGROUND OF THE INVENTION

Many traditional machining processes utilize a “wet machining” process that requires the application of a large quantity of lubricating coolant to an interface between a cutting tool and a workpiece during a machining process. Such machining processes may include milling, drilling, tapping, and finish machining, for example. The lubricating coolant used may be water or oil-based, and such machining processes may require the delivery of several gallons per hour of the lubricating coolant to the cutting edge of the cutting tool to maintain a thermal stability of the machine tooling and the workpiece. The wet machining process may also be used to desirably relocate chips that are removed from the workpiece as a result of the machining process.

However, use of traditional wet machining processes can be problematic due to the additional expense required to maintain a system utilizing such large quantities of lubricating coolant. For instance, it has been estimated that the costs associated with the use of a suitable lubricating coolant in a wet machining process can be as much as 15% or more of the life-cycle operational cost of the machining process. These costs may include the expenses associated with procuring, filtering, or separating the lubricating coolant, as well as expenses related to keeping records and disposing of the lubricating coolant in accordance with any applicable rules or regulations related to the use of such coolants.

Wet machining processes also present additional safety and health concerns for those who operate such systems. Traditional wet machining often results in the formation of a coolant mist that may interact with the remainder of the work shop where the wet machining is being performed. The coolant mist may present health concerns due to its toxicity and the generation of bacteria or fungi associated with the coolant.

One solution to the problems associated with wet machining is the use of minimum quantity lubrication (MQL) machining processes. An MQL machining process is a nearly dry machining process that uses a small quantity of a lubricant, such as vegetable or ester-based oil, mixed with a gas such as air to form an aerosol for lubricating a cutting tool surface during a machining process. MQL machining requires only milliliters of lubricant to be delivered to the cutting edge of the tool per hour as opposed to the gallons of coolant per hour associated with a wet machining process. This significant reduction in the use of lubricant causes an MQL machining process to reduce the exposure of workers to the harmful coolant mists used in wet machining processes, to reduce the amount of materials that must be disposed of following the machining process, and to produce nearly dry and virtually clean metal chips that are much easier to recycle.

Many cutting tools used to carry out an MQL process require internal passages or ducts to supply the air and oil aerosol to the cutting edge of the tool. Such MQL machining processes require that the aerosol flowing through such passages be precisely metered to maintain optimum wetting and lubrication properties, depending on the type of cutting operation. If the aerosol passing through the passages formed in the cutting tool encounters a significant pressure drop or for any other reason is not allowed to flow freely during rotation of the cutting tool the aerosol will reclassify as a larger globule of oil, and the precisely selected lubricity properties of the aerosol will be lost. The resulting loss of lubrication may cause significant damage to the cutting tool, the workpiece, or both.

Additionally, the degree of pressure drop encountered by a lubricating aerosol is often directly affected by the shape and configuration of the fluid conduit through which the lubricating aerosol is caused to flow. Even minor changes in the diameter or curvature of such a fluid conduit can have significant effects on the degree of pressure drop encountered by the lubricating aerosol as it traverses the fluid conduit. Accordingly, it is important that any fluid conduits used to distribute such a lubricating aerosol are precision manufactured to ensure that the lubricating aerosol is delivered to each of the cutting edges of the cutting tool while having a pressure suitable for preventing the separation of the lubricating oil and the air forming the lubricating aerosol.

It would therefore be desirable to create a tool that includes internal fluid conduits that are precision manufactured to militate against causing a pressure drop in a lubricating aerosol traversing the internal fluid conduits during a cutting operation of the tool.

SUMMARY OF THE INVENTION

In accordance with the present invention, a cutting tool having internal fluid conduits that militate against causing a pressure drop in an aerosol passing therethrough is disclosed.

In an embodiment of the current invention, a lubricant distribution device is configured to be coupled to a rotating cutting tool having a plurality of circumferentially spaced cutting surfaces. The lubricant distribution device comprises a main body having a manifold conduit extending along a central rotational axis of the main body and a plurality of lubricant distributing conduits formed in the main body and extending radially outwardly from the manifold conduit. Each of the lubricant distributing conduits is configured to convey a lubricant therethrough and includes an inlet fluidly coupling each of the lubricant distributing conduits to the manifold conduit and an outlet disposed adjacent a corresponding one of the circumferentially spaced cutting surfaces of the cutting tool.

In another embodiment of the current invention, a rotating cutting tool comprises a cylindrical main body including an end face and an outer circumferential surface including a plurality of circumferentially spaced cutting surfaces. The rotating cutting tool further comprises a lubricant distribution cap configured to mate with the end face of the cylindrical main body. The lubricant distribution cap includes a manifold conduit extending along a central rotational axis thereof and a plurality of lubricant distributing conduits extending radially outwardly from the manifold conduit. Each of the lubricant distributing conduits is configured to convey a lubricant therethrough and includes an inlet fluidly coupling each of the lubricant distributing conduits to the manifold conduit and an outlet disposed adjacent a corresponding one of the circumferentially spaced cutting surfaces of the cylindrical main body.

DETAILED DESCRIPTION OF THE INVENTION

The following description of technology is merely exemplary in nature of the subject matter, manufacture and use of one or more inventions, and is not intended to limit the scope, application, or uses of any specific invention claimed in this application or in such other applications as may be filed claiming priority to this application, or patents issuing therefrom. Additionally, the dimensions provided in the drawings are merely for purposes of explaining the invention, and are not necessary or critical to operation of the invention unless otherwise stated herein. In respect of the methods disclosed, the steps presented are exemplary in nature, and thus, the order of the steps is not necessary or critical.

FIGS. 1 and 2illustrate a lubricant distribution device in the form of a cap10having a main body including a stem20, a collar30, and a flanged portion40. The lubricant distribution cap10is used to distribute a lubricant during an MQL machining process. The lubricant may be a lubricating aerosol comprising a gas, such as air, mixed with a lubricant, such as vegetable or ester-based oil, for example. However, it should be understood that any form of lubricating aerosol suitable for use with the lubricant distribution cap10may be used without departing from the scope of the present invention.

The lubricant distribution cap10is configured for use with a rotating cutting tool3. The rotating cutting tool3may be configured to perform any known machining operation relying on a rotational motion of an associated cutting surface. The rotating cutting tool3may for instance be a milling cutting machine, as desired.

The rotating cutting tool3may include an annular cutting tool main body4having one or more circumferentially spaced recesses or pockets5configured to receive a cutting tool cartridge6therein. The cutting tool cartridge6may have a shape and configuration to be secured within one of the pockets5of the cutting tool body4and the cutting tool cartridge6may be secured into one of the respective pockets5by means of a clamping screw (not shown) or other known securing means. The cutting tool cartridge6may further be configured for retention of a cutting insert (not shown) for removing material from a workpiece during a machining process. An example of a rotating cutting tool that may be adapted for use with the lubricant distribution cap10is disclosed in U.S. Pat. No. 9,266,174, which is hereby incorporated herein by reference in its entirety.

The stem20includes a freely disposed first end21and a second end22coupled to the collar30. The stem20may be substantially cylindrical in shape. An exterior circumferential surface24of the stem20may include a coupling feature disposed thereon for coupling the lubricant distribution cap10to the rotating cutting tool3. For instance, the rotating cutting tool3may include a coupling feature such as a threaded aperture7formed along a central rotational axis thereof adapted to receive the stem20, and the exterior circumferential surface24of the stem20may include threads formed thereon adapted to mate with the threads of the threaded aperture7to secure the lubricant distribution cap10to the rotating cutting tool3. It should be understood, however, that any suitable means of securing the lubricant distribution cap10to the rotation cutting tool3may be used, as desired.

The lubricant distribution cap10further includes a manifold conduit50and a plurality of lubricant distributing conduits60branching from the manifold conduit50. The manifold conduit50extends through an interior of the stem20and the collar30along a central rotational axis of the lubricant distribution cap10. The manifold conduit50includes an inlet51formed adjacent the first end21of the stem20and an outlet52formed adjacent an interface of the collar30and the flanged portion40. The inlet51may be aligned with a corresponding fluid passageway8formed in the rotating cutting tool3at a base of the threaded aperture7when the lubricant distribution cap10is securely coupled to the rotating cutting tool3.

The collar30is a cylindrical portion of the lubricant distribution cap10interposed between the stem20and the flanged portion40. The collar30may be adapted to aid in properly locating the lubricant distribution cap10when the lubricant distribution cap10is coupled to the rotating cutting tool3.

The flanged portion40is substantially frustoconical and disk-like in shape and is connected to a surface of the collar30opposite the stem20. An exterior surface of the flanged portion40includes a substantially circular and planar outer face42spaced apart from the collar30, an angled surface43extending outwardly from the collar30, and a circumferential surface47connecting the outer face42to the angled surface43and arranged substantially parallel to the central rotational axis of the lubricant distribution cap10. The angled surface43may be angled at about 5-10° with respect to the outer face42, but any suitable angle may be used without departing from the scope of the present invention.

The stem20, the collar30, and the flanged portion40may be formed to have a rotationally symmetric shape capable of mating with an exterior face9of the rotating cutting tool3to which the lubricant distribution cap10is to be secured. Accordingly, the dimensions and angles of the surfaces forming the lubricant distribution cap10may be adapted for use with any number of rotating cutting tools having variable sizes and mating surface configurations without departing from the scope of the present invention.

The outlet52of the manifold conduit50is fluidly coupled to an inlet61of each of the plurality of the lubricant distributing conduits60. As best shown inFIG. 2, the conduits60extend radially outwardly from the central rotational axis of the lubricant distribution cap10and toward the circumferential surface47of the flanged portion40. Each of the conduits60includes an outlet62formed in or adjacent the circumferential surface47of the flanged portion40, resulting in the outlets62being circumferentially spaced apart around the periphery of the flanged portion40. The outlets62may also be formed in the outer face42or the angled surface43of the flanged portion40adjacent the circumferential surface47, as desired, if an alternate angle of delivery of the aerosol is required.

Although the lubricant distribution cap10is shown as having twelve (12) of the conduits60, it should be understood that any number of conduits60may be formed in the lubricant distribution cap10. Rotating cutting tools adapted for use with the lubricant distribution cap10may include any number of cutting tool surfaces in need of lubrication during a cutting operation. The number of conduits60formed in the lubricant distribution cap10is therefore dependent on the number of cutting surfaces formed on the rotating cutting tool to which the lubricant distribution cap10is coupled. Accordingly, the outlet62of each of the conduits60may be formed in the flanged portion40of the lubricant distribution cap10at a location where each outlet62will be disposed adjacent and directed toward a corresponding cutting surface spaced around the periphery of the rotating cutting tool3.

As best shown inFIG. 1, each of the conduits60may include a transitional portion63formed adjacent the inlet61thereof. The transitional portion63causes each of the conduits60to turn from extending in a direction substantially parallel to the manifold conduit50to a direction substantially perpendicular to the manifold conduit50. Each of the transitional portions63bends around an axis arranged perpendicular to the central rotational axis of the lubricant distribution cap10. As shown inFIG. 1, the conduits60may also be angled with respect to the outer face42of the flanged portion40as each of the conduits60extends from the transitional portion63thereof to the circumferential surface47of the flanged portion40. The conduits60may angled between 0 and 10 degrees relative to the outer face42, as desired.

Each of the conduits60may have a substantially circular or elliptical cross-sectional shape. The circular or elliptical cross-sectional shape beneficially prevents a fluid flowing through each of the conduits60from encountering a significant pressure drop due to lack of sharp edges or corners in each of the conduits60.

Each of the inlets61of the plurality of the conduits60may have a common internal cross-sectional flow area, and in the case of a substantially circular conduit60, a common inner diameter. A total combined flow area of each of the inlets61is selected to be substantially equal to a flow area of the manifold conduit50at the outlet thereof52. The equality of the flow area of the outlet52of the manifold conduit50and the total flow area of the combined inlets61of the conduits60beneficially prevents a pressure drop from occurring in the aerosol as it enters the plurality of the conduits60because a total mass flow of the aerosol is not altered at the transition from the manifold conduit50to the plurality of the conduits60, thereby allowing the aerosol to enter the conduits60without undergoing a significant change in velocity and therefore pressure.

Each of the conduits60may have a variable internal cross-sectional flow area as each of the conduits60extends from the inlet61thereof to the outlet thereof62. In some embodiments, each of the conduits60has a substantially constant internal flow area along the transitional portion63thereof and a first portion of each of the conduits60formed adjacent and extending from the transitional portion63. A second portion of each of the conduits60formed between the first portion and the outlet62thereof may include a continuously and gradually decreasing internal flow area. In the case of conduits60having a substantially circular cross-sectional shape an inner diameter of each of the conduits60may be decreased in a manner wherein the second portion of each of the conduits60is substantially frustoconical in shape with a very small degree of inward tapering. In other embodiments, each of the conduits60has a continuously and gradually decreasing internal flow area along a length of each of the conduits60extending from the transitional portion63to the outlet62thereof. Still, in other embodiments, each of the conduits60may include at least one portion formed between the inlet61thereof and the outlet62thereof wherein the internal flow area of each of the conduits60first increases continuously and gradually before again continuously and gradually decreasing in internal flow area adjacent the outlet62thereof.

The decreasing of the internal flow area of each of the conduits60adjacent the outlet62thereof acts to increase a velocity of the aerosol immediately prior to the aerosol exiting each of the conduits60. The increased velocity of the aerosol at each of the outlets62beneficially promotes the removal of cutting chips adjacent each of the cutting surfaces of the rotating cutting tool3that may be generated during the cutting process.

However, the degree and the rate of the decrease in the internal flow area of each of the conduits60is controlled to ensure that an excessive pressure drop does not occur within the aerosol due to the increase in velocity of the aerosol when encountering the reduced internal flow area. If a pressure of the aerosol is decreased beyond a specified value, the oil-based lubricant of the aerosol may precipitate out of the aerosol suspension, causing the aerosol being distributed by the outlets62of the conduits60to not have the desired lubricating properties. Accordingly, the degree, the positioning, and the rate of the decrease in the internal flow area of each of the conduits60is selected to promote a desired increase in the velocity of the aerosol adjacent the outlet62thereof while also ensuring that the aerosol does not undergo a great enough degree of pressure drop to cause the aerosol to separate before being ejected from each of the conduits60. Additionally, it should be understood that portions of each of the conduits60may similarly be selected to have the increasing internal flow area to similarly control a velocity and a pressure of the aerosol, as desired.

In use, the lubricant distribution cap10is first secured to the rotating cutting tool3via the securing means formed on the stem20. Once properly located and secured, the inlet51of the manifold conduit50is aligned with the fluid passageway8formed in the rotating cutting tool3, allowing for fluid communication between a source of the aerosol and the manifold conduit50. The rotating cutting tool3is caused to rotate about the central rotational axis thereof and the aerosol is continuously fed from a source of the aerosol (not shown) to the manifold conduit50of the lubricant distribution cap10before being continuously distributed to the plurality of lubricant distributing conduits60. At least a portion of each of the conduits60includes an internal flow area that decreases gradually toward the outlet62of each of the conduits60in a manner wherein a pressure of the aerosol flowing through each of the conduits60does not undergo a significant pressure drop to cause the aerosol to come out of suspension while a velocity of the aerosol is also increased.

The aerosol flows through each of the conduits60before being ejected from the lubricant distribution cap10via the plurality of outlets62distributed around a periphery of the flanged portion40. Each of the outlets62is formed in the lubricant distribution cap10such that each of the outlets62directs the aerosol to a specified cutting surface similarly spaced around a periphery of the rotating cutting tool3. The lubricant distribution cap10is configured to distribute a preselected quantity of the aerosol to each of the cutting surfaces formed on the rotating cutting tool3at a preselected rate, depending on the type of the rotating cutting tool3and the desired application. The aerosol is continuously fed to each of the outlets62regardless of which of the associated cutting surfaces are engaging an associated workpiece during use of the rotating cutting tool3. The aerosol may be distributed out of the outlets62at a rate of about 250 milliliters per hour, but any suitable rate may be used, as desired.

FIGS. 3 and 4illustrate a lubricant distribution cap110according to another embodiment of the invention. Structure similar to that illustrated inFIGS. 1 and 2includes the same reference numeral and a prime (′) symbol for clarity. The lubricant distribution cap110includes a main body including a stem20′, a collar30′, and a flanged portion40′ all having substantially similar structure to the stem20, the collar30, and the flanged portion40of the lubricant distribution cap10. However, the lubricant distribution cap110includes internal lubricant distributing conduits160having a different structure from the lubricant distributing conduits60of the lubricant distribution cap10illustrated inFIGS. 1 and 2.

Each of the conduits160includes an inlet161and an outlet162. In similar fashion to the lubricant distribution cap10illustrated inFIG. 1, each of the conduits160further includes a transitional portion163. The transitional portion163of each of the conduits160causes the aerosol to change from flowing in a direction substantially parallel to the central rotational axis of the lubricant distribution cap110to a direction transverse to and extending substantially radially outwardly therefrom. Each of the conduits160further includes a bend165formed in a portion of each of the conduits160disposed radially outwardly from the transitional portion163thereof. The bends165cause each of the conduits160to bend around an axis arranged parallel to the central rotational axis of the lubricant distribution cap110. Each of the bends165includes a first end166(shown inFIG. 3) adjacent the transitional portion163thereof and a second end167(shown inFIG. 4) formed at the outlet162thereof. Each of the bends165may have a substantially constant radius of curvature extending from the first end166to the second end167thereof or each of the bends165may have a variable radius of curvature extending from the first end166to the second end167thereof, as desired. As shown inFIG. 4, each of the bends165may for example have a large radiused bend165wherein the radius of curvature of each of the bends165is greater than a radius of the lubricant distribution cap110. In other embodiments, smaller radii of curvature may be used, as desired.

The bends165cause each of the conduits160to have an outlet162that is directed at least partially in a direction extending radially outwardly and perpendicular to the circumferential surface47′ as well as at least partially in a direction tangential to the circumferential surface47′. Accordingly, each of the bends165allows for the aerosol to be ejected from each of the outlets162in a direction that is not entirely perpendicular to the circumferential surface47′ of the flanged portion40′ in contrast to the configuration of the lubricant distribution cap10illustrated inFIG. 2. Such a configuration is beneficial when a desired machining process requires that the lubricant be delivered at a specific angle relative to the workpiece or when the removal of the resulting cutting chips requires the chips to be ejected in a desired direction.

Referring toFIG. 4, the rotating cutting tool3to which the lubricant distribution cap110is to be coupled is caused to rotate in the direction A during use thereof. Accordingly, each of the bends165is selected to cause each of the outlets162to be directed in a tangential direction opposite of the direction of rotation A of the rotating cutting tool3. In other words, each of the bends165turn in a direction that is opposed to the direction of rotation of the rotating cutting tool3as each of the conduits160extend from the inlet161thereof to the outlet162thereof.

The inclusion of a radiused bend165in each of the conduits160beneficially allows for the aerosol to be changed from being directed in the radial outward direction to being directed at least partially in the tangential direction without undergoing a significant pressure drop due to the aerosol not encountering a sudden or sharp change in direction. Accordingly, the radius of each of the bends165is selected to result in each of the outlets162being directed at a desired angle relative to the circumferential surface47′ while also being selected to ensure that a pressure drop sufficient to cause the aerosol to fall out suspension does not occur as the aerosol traverses each of the bends165.

Each of the conduits160may further include a variable internal flow area as each of the conduits160extends from the inlet161thereof to the outlet162thereof. More specifically, each of the conduits160may be formed to have a continuously and gradually decreasing internal flow area towards the outlet162of each of the conduits160to promote an increased velocity of the aerosol adjacent each of the associated cutting surfaces of the rotating cutting tool3. As explained hereinabove, the length and rate of change in the portion of each of the conduits160having the decreasing internal flow area may be selected to prevent the aerosol from experiencing an excessive pressure drop capable of bringing the aerosol out of suspension while also causing the aerosol to be ejected at a desired velocity. Additionally, each of the conduits160may further include at least a portion thereof having an increasing internal flow area without departing from the scope of the present invention.

In use, the lubricant distribution cap110operates in substantially similar fashion to the lubricant distribution cap10. The rotating cutting tool3is caused to rotate in the direction A and the aerosol is delivered through the rotating cutting tool3to the lubricant distribution cap110. The aerosol flows through the manifold conduit (not shown) formed in the stem20′ before being distributed to the plurality of the aerosol distributing conduits160formed in the flanged portion40′. The aerosol then flows through the inlet161, the transition portion163, the bend165, and the outlet162of each of the conduits160before striking the desired cutting surface. As described hereinabove, the decreasing internal flow area of the conduits160and the curvature of the bends165aid in directing the aerosol at a desired angle and velocity while also ensuring that the aerosol does not undergo an undesirable degree of pressure drop.

FIG. 5illustrates a lubricant distribution cap210according to another embodiment of the invention. The lubricant distribution cap210is substantially identical to the lubricant distribution cap110except the lubricant distribution cap210includes lubricant distributing conduits260that include each of a first linear portion266, a second linear portion267, and a bend265connecting the first linear portion266to the second linear portion267. The first linear portion266extends from a transitional portion263of each of the conduits260formed adjacent a central rotational axis of the lubricant distribution cap210to the bend265thereof. The second linear portion267extends from the bend265to an outlet262of each of the conduits260. Each of the bends265curves around an axis arranged parallel to the central rotational axis of the lubricant distribution cap210. The bends265cause the second linear portion267of each of the conduits260to be angled with respect to the first linear portion266of each of the conduits260, thereby causing the outlet262of each of the conduits260to similarly be angled with respect to the first linear portion266of each of the conduits260. The angle formed between the first linear portion266and the second linear portion267may be between about 30-60°, but it should be understood that other angles may be selected without departing from the scope of the current invention. The bend265in each of the conduits260is selected to result in a desired angle of ejection of the aerosol flowing through each of the conduits260while also preventing the aerosol from losing enough pressure to come out of suspension.

Each of the conduits260may further include at least a portion thereof having a variable internal flow area to control for a velocity or pressure of the aerosol as it traverses each of the conduits260. For example,FIG. 5illustrates each of the conduits260as including a second linear portion267having a decreasing internal flow area as the second linear portion267extends from the bend265to the outlet262of each of the conduits260. In other embodiments, each of the conduits260may include portions of both increasing and decreasing internal flow area, as desired.

The internally formed conduits60,160,260form complex shaped voids in each of the caps10,110,210having multiple turns and curved or angled surfaces. The unique geometries of the conduits60,160,260, which may include a decreasing internal diameter and various curved portions, require that the lubricant distribution caps10,110,210be formed using a 3-dimensional additive manufacturing process in place of a traditional manufacturing process, as many traditional manufacturing processes cannot recreate such complex geometries while remaining within desired tolerances. For example, traditional molding or casting operations suffer from issues of excessive porosity, inconsistent fill density, and the inability to create complex shapes during a single manufacturing process. It is also difficult to manufacture complex internal voids using traditional machining processes, and the traditional machining processes further present issues relating to burring and other inconsistencies that must be removed from each of the internal voids following the formation thereof.

The inability for complex internal voids to be manufactured in a single process often results in internal voids that must be formed by the cooperation of multiple parts, which presents additional issues of component alignment, sealing, and the introduction of undesired surfaces and edges that could potentially affect the flow of a fluid encountering the surfaces or edges. Accordingly, the geometries and the precise dimensioning required to create the desired pressure and velocity of the aerosol to be distributed by each of the lubricant distribution caps10,110,210requires the 3-dimensional additive manufacturing process.

The 3-dimensional additive manufacturing process may for instance be a selective laser sintering process wherein each of the conduits60,160,260is formed as a void during the selective laser sintering process. The lubricant distribution caps10,110,210may be formed from any material suitable for a 3-dimensional additive manufacturing process and capable of withstanding the external forces and internal pressures encountered by the lubricant distribution caps10,110,210. One suitable material for forming the lubricant distribution caps10,110,210may be titanium, for example. Other forms of additive manufacturing processes capable of achieving desired tolerances may similarly be used in place of laser sintering. Additionally, other materials in addition to titanium may be used without departing from the scope of the present invention.

In some embodiments the 3-dimensional additive manufacturing process is used to form only those portions of each of the caps10,110,210having the conduits60,160,260formed therein due to the complex geometries of each of the conduits60,160,260. For example, with reference toFIG. 1, the stem20and the collar30may be formed separately from the flanged portion40having the conduits60formed therein. The stem20, the collar30, and the flanged portion40can then be assembled to align the manifold conduit50of the stem20and the collar30with each of the inlets161formed in the flanged portion40. In other embodiments, the entirety of each of the lubricant distribution caps10,110,210is formed using the 3-dimension additive manufacturing process.

It should also be understood that although the conduits60,160,260are disclosed as being formed in a lubricant distribution cap10,110,210that is then coupled to a suitable rotating cutting tool3, the conduits60,160,260could also be formed integrally with the rotating cutting tool3, removing the need for a separately formed lubricant distribution cap10,110,210.