Active-Pressure Hole Finishing Tool for Single-Setup Bore Rework
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Solution Overview
Problem
Conventional cutting tools require multiple steps and tool changes for drilling, deburring, and cold working or burnishing boreholes, increasing manufacturing time and expense.
Innovation Solution
An active-pressure cutting tool with a material reworking attachment that can transition between drilling, deburring, chamfering, and surface-finishing positions, using a piston or electric actuator to apply pressure for deburring, cold working, and burnishing within a single tool.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple separate tools are used for drilling, deburring, and cold working/burnishing, then each operation can be performed with a specialized tool, but the manufacturing time increases and multiple tool changes are required
Solution Approach 1:
The patent combines drilling, deburring, chamfering, cold working, and burnishing functions into a single integrated tool. The tool includes a drill bit for drilling, a material reworking attachment with chamfering blades for deburring and chamfering, and a finishing attachment with rollers for cold working and burnishing. This merging eliminates the need for multiple tool changes and reduces manufacturing time.
Solution Approach 2:
The single tool is designed to perform multiple functions: the drill bit creates the borehole, the material reworking attachment deburrs and chamfers the hole edges, and the finishing attachment cold works and burnishes the borehole surface. This multi-functionality allows one tool to replace several specialized tools, improving productivity while managing device complexity.
2Productivity
If multiple tool changes are made for different operations, then each operation can be optimized with the appropriate tool, but the manufacturing expense increases
Solution Approach 1:
By merging multiple specialized tools into one integrated tool, the patent eliminates the costs associated with multiple tool changes, including tool setup time, tool handling, and potential positioning errors. The single tool approach reduces manufacturing expense while maintaining operational effectiveness through its multi-functional design.
3Productivity
If a single tool performs multiple functions, then manufacturing time is reduced and productivity increases, but the tool structure becomes more complex
Solution Approach 1:
The patent employs a nested structure where the material reworking attachment and finishing attachment can be stored within the drill body when not in use. The attachments extend from the drill body during their respective operations and retract into the drill body for tool changes or storage. This nesting approach manages the complexity of having multiple functions in one tool by organizing components in a compact, hierarchical arrangement.
Solution Approach 2:
The tool incorporates dynamic elements including the extendable/retractable attachments and the active-pressure system with piston and control valve that allows the finishing attachment to apply variable pressure to the borehole wall. This dynamic capability enables the tool to adapt its structure and function during operation, managing complexity through controlled movement and adjustment rather than fixed rigid components.
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 solution reduces manufacturing time by integrating multiple functions into a single tool, allowing for efficient deburring, chamfering, cold working, and burnishing without the need for multiple tool changes, thereby enhancing production efficiency and join strength.
Implementation Method 1
The piston is in fluid communication with a variable control valve that controls a pressure of a fluid that applies a force to the piston
Data Source
AI summary
Provided is cutting tool. The tool, in certain examples, includes a drill body that defines a drill axis, and a tool window formed in the drill body. The tool also includes a drill bit extending from the drill body, and a material reworking attachment (“MRA”) coupled to the drill body and storable within the tool window. The MRA is extendable from a stored position into either a surface-finishing position or a material-removal position. The MRA includes a first chamfering blade, a second chamfering blade, and a finishing surface interposed between the chamfering blades. The tool also includes a position manager to detect a position of the cutting tool with reference to a workpiece, and an actuator to transition the MRA from the stored position to the material-removal position, followed by a transition to the surface-finishing position, and followed by a transition to material-removal position.