Bore Undercutting Tool for Adhesive-Locked Insert Anchoring
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Solution Overview
Problem
Existing connection methods for components, particularly plastics, face instability due to the detachment of adhesives from smooth bores, leading to potential damage and failure of the screw connection, as the metal screw can be pulled out, necessitating an improved anchoring solution for inserts within these components.
Innovation Solution
A cutting tool with a shaft portion and tangentially and axially cutting portions is used to create undercut and introducing grooves within the bore of a component, allowing for a secure adhesion of an insert element by forming a form fit with the adhesive, reducing the risk of detachment and enhancing the structural integrity of the connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a smooth cylindrical bore is used for adhesive bonding, then the manufacturing process is simple, but the adhesive can become detached together with the insert
Solution Approach 1:
The cutting tool creates undercut grooves in the bore wall before the adhesive is applied. This preliminary action of forming the groove structure ensures that the adhesive will mechanically interlock with the bore, preventing detachment under load. The grooves are formed by cutting portions with cutting edges that remove material to create the anchoring structure.
Solution Approach 2:
The cutting tool divides the bore surface into multiple grooves that segment the adhesive bonding area. These grooves create multiple anchoring points along the bore wall, distributing the stress and preventing the adhesive from detaching as a single unit. The grooves are formed by the cutting portions moving through the bore to create a segmented surface structure.
2Device complexity
If a metal screw is directly screwed into a plastic part, then the connection process is simple, but the screw can be pulled out due to the plastic's lower strength
Solution Approach 1:
An insert element is introduced as an intermediary component between the screw and the plastic part. The insert is anchored into the bore using adhesive bonding with the undercut groove structure, creating a strong mechanical interlock. The screw then engages with the insert, which has higher strength than the plastic, preventing pull-out while maintaining a relatively simple connection process.
3Strength
If an insert is adhesively bonded into a smooth bore, then the insert provides material stability, but the adhesive connection is not secure under load
Solution Approach 1:
The surface parameters of the bore are changed by creating undercut grooves that alter the geometric structure. This changes the bonding interface from a smooth surface to a structured surface with mechanical interlocking features. The grooves increase the surface area and create physical anchors that prevent adhesive detachment, making the bond reliable under load while maintaining the insert's material strength.
Data Source
AI summary
A cutting tool for undercutting a bore in a component includes a shaft portion and at least one tangentially and axially cutting portion. The shaft portion extends in an axial direction relative to the component and has a maximum shaft radius. The cutting portion projects radially with respect to the shaft portion further than the maximum shaft radius. Each cutting portion includes a tangentially arranged lateral cutting edge configured to form a tangentially extending groove in the component. At least one cutting portion has a front cutting edge arranged axially at a front end thereof and configured to form an axially extending groove in the component.