Additive Burnishing Tool with Integrated Fluid Passageways
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Solution Overview
Problem
Conventional burnishing tools have complex fluid supply systems that are costly, time-consuming to assemble, and prone to leaks, limiting their cooling and lubrication performance and manufacturing efficiency.
Innovation Solution
The burnishing tool features additively manufactured upper and lower nozzles with integrated cooling channels and a burnishing element that provides fluid communication, simplifying the assembly and enhancing cooling and lubrication through internal fluid passageways, reducing the number of components and potential leaks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional separate fluid supply systems with multiple manifolds and conduits are used, then cooling and lubrication can be provided, but device complexity increases and reliability decreases due to multiple joints and assembly steps
Solution Approach 1:
The patent merges multiple separate fluid supply components (manifolds, conduits, support structures) into a single integrated burnishing tool body with internal fluid passageways. The fluid distribution system is combined with the tool structure itself, eliminating the need for separate assemblies and reducing the number of joints from multiple connections to a single integrated unit, thereby improving reliability and reducing complexity.
Solution Approach 2:
The burnishing tool body serves multiple functions: it provides structural support for burnishing operations, contains internal fluid passageways for cooling and lubrication, and acts as the fluid distribution system. This multi-functional design eliminates the need for separate fluid supply components, reducing device complexity while maintaining comprehensive cooling and lubrication capabilities.
2Ease of manufacture
If multiple separate fluid supply components are assembled, then fluid distribution can be achieved, but manufacturing time and assembly costs increase significantly
Solution Approach 1:
The patent combines fluid supply channels, cooling passages, and structural elements into a single monolithic burnishing tool body manufactured via additive manufacturing. This integration eliminates multiple assembly steps and reduces manufacturing time from assembling numerous separate components to producing one integrated part, directly addressing the time loss and manufacturing efficiency issues.
Solution Approach 2:
The patent employs additive manufacturing technology to create complex internal fluid passageways that would be impossible or extremely difficult to manufacture using conventional methods. This manufacturing parameter change enables the production of integrated components with intricate internal structures in a single build process, dramatically reducing assembly time and improving manufacturing efficiency.
3Reliability
If conventional fluid supply systems are used, then cooling and lubrication can be provided, but the likelihood of fluid leaks increases due to multiple joints and connections
Solution Approach 1:
The patent integrates the fluid distribution system directly into the burnishing tool body, creating internal fluid passageways that are part of the monolithic structure. This eliminates multiple external joints and connections where leaks could occur, reducing the leak risk from numerous connection points to a single integrated structure with internal channels that have no external joints.
4Device complexity
If additive manufacturing is used to create integrated nozzles with internal passageways, then device complexity is reduced and assembly is simplified, but manufacturing precision requirements increase
Solution Approach 1:
The patent utilizes additive manufacturing technology, which changes the manufacturing approach from conventional subtractive or assembly-based methods to a layer-by-layer deposition process. This parameter change enables the creation of complex internal fluid passageways and integrated structures that would be impossible to manufacture otherwise, achieving simplified assembly while managing manufacturing precision through process control and post-processing techniques.
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 improves the manufacturing efficiency, reduces assembly costs, and enhances the cooling and lubrication performance of the burnishing tool by integrating fluid passageways within a single monolithic component, reducing the complexity and likelihood of leaks in the fluid supply system.
Implementation Method 1
depositing a layer of additive material on a bed of an additive manufacturing machine and selectively directing energy from an energy source onto the layer of additive material to fuse a portion of the additive material
Data Source
AI summary
A burnishing tool and a method of additively manufacturing components of the burnishing tool are provided. The burnishing tool includes a burnishing element for burnishing a workpiece. The burnishing element is positioned between an upper nozzle and a lower nozzle which are additively manufactured to define a plurality of internal fluid passageways for receiving, distributing, and discharging a burnishing fluid to facilitate cooling and/or lubrication of the burnishing element and/or the workpiece.