Boring Tool Stabilizing Structure for Low-Stress Machining
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Solution Overview
Problem
Conventional boring tools for widening recesses in metal workpieces are heavy, leading to significant mechanical stresses and tilting moments during machining, which can result in dynamic forces and reduced machining efficiency.
Innovation Solution
A boring tool design featuring a stabilizing structure with a core element surrounded by an outer wall, where the connection structure is monolithically connected without material seams, and includes helical elements that counteract torsional deformation by dissipating deformation energy and enhancing the area moment of inertia, thereby reducing weight and mechanical stresses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the boring tool uses a conventional heavy design to ensure stability, then deformation resistance is improved, but weight increases leading to larger tilting moments and spindle loads
Solution Approach 1:
The stabilizing structure is divided into multiple discrete connecting elements (first connecting element, second connecting element, third connecting element) distributed around the core structural element. This segmentation provides effective stabilization against deformation while using less material than a solid heavy construction, thereby reducing weight and associated tilting moments.
Solution Approach 2:
The boring tool employs a composite structural design combining a core structural element with an outer wall and intermediate stabilizing connecting elements. This composite architecture achieves high deformation resistance through the synergistic arrangement of different structural components rather than relying on uniform heavy material distribution, reducing overall tool weight.
2Productivity
If the boring tool rotates at high speed to improve productivity, then machining efficiency is improved, but dynamic forces and mechanical stresses increase
Solution Approach 1:
Instead of increasing tool mass to counteract dynamic forces during high-speed rotation, the invention inverts the approach by using a lightweight core structural element surrounded by strategically positioned stabilizing connecting elements. This provides necessary rigidity to withstand dynamic forces at high rotational speeds without the penalty of increased weight.
Solution Approach 2:
The stabilizing structure extends in the radial direction with connecting elements positioned between the core structural element and outer wall at specific radial distances. This three-dimensional arrangement provides effective resistance to dynamic forces during high-speed rotation while maintaining minimal mass, enabling high productivity without excessive mechanical stresses.
3Weight of moving object
If the outer wall is made thinner to reduce weight, then tool weight is reduced, but deformation stability of the outer wall deteriorates
Solution Approach 1:
Connecting elements serve as intermediary components positioned between the core structural element and the outer wall. These intermediaries provide direct structural support to the thinner outer wall, preventing deformation while allowing the outer wall to maintain reduced thickness for weight savings. The connecting elements transfer and distribute loads effectively.
Solution Approach 2:
The stabilizing structure utilizes the radial dimension by positioning connecting elements at specific radial distances from the core structural element (e.g., 0.05-0.15 times the outer diameter). This three-dimensional configuration provides effective deformation stability to the thin outer wall without requiring increased wall thickness, maintaining weight reduction benefits.
Data Source
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AI summary
In order to provide a boring tool (1) for at least partially widening a recess in a metallic workpiece by rotating it about a longitudinal axis (2) in a predetermined machining direction (3), comprising a one- or multi-part outer wall (4) and several cutting elements (200) arranged in a one- or multi-part receiving structure (5) of the outer wall (4), which reduces the mechanical stresses during boring in an improved manner, it is proposed that a stabilizing structure (14, 16, 17, 18, 19, 20, 21, 22, 23, 25, 26, 27, 28) for inhibiting deformation of the outer wall (4) is designed such that a core structural element (14, 25, 26, 27, 28) of the stabilizing structure (14, 16, 16, 18, 19, 20, 21, 22, 23, 25, 26, 27, 28) of the stabilizing structure (14, 16 ... 17, 18, 19, 20, 21, 22, 23, 25, 26, 27, 28) is spaced from the outer wall (4), in a space between the core structural element (14, 25, 26, 27,28) and the outer wall (4) formed a space (4b) formed by a connecting structure (16, 17, 18, 19, 20, 21, 22, 23) of the stabilizing structure (14, 16, 17, 18, 19, 20, 21, 22, 23, 25, 26, 27, 28), the space (4b) is divided by the connecting structure (16, 17, 18, 19, 20, 21, 22, 23) into a stabilizing structure-free area and a stabilizing structure-containing area (16, 17, 18, 19, 20, 21, 22, 23, 25, 26, 27, 28) and the connecting structure (16, 17, 18, 19, 20, 21, 22, 23) is monolithically connected to the outer wall (4) and the core structural element (14, 25, 26, 27, 28) without any material seams.