Box-End Wrench Through-Hole Tooling for One-Step Punching and Cutting
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Solution Overview
Problem
The traditional manufacturing method of box-end wrenches is complex and costly, requiring multiple special processing machines for forging, punching, and broaching.
Innovation Solution
A machining tool comprising a fixed pillar, cutting tool unit, and support member, which includes a punching tool, rough cutting tool, and finishing cutting tool, allowing sequential processing of a through hole in a single operation, with spacers for chip discharge and tool exchange convenience.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple special processing machines are used for forging, punching, and broaching, then the manufacturing precision and reliability are improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines punching, rough cutting, and finishing cutting functions into a single integrated machining tool. The tool includes a punching tool portion, rough cutting tool portion, and finishing cutting tool portion that all operate sequentially in one clamping position, eliminating the need for multiple separate machines and reducing process complexity while maintaining precision
Solution Approach 2:
The machining tool is designed as a multi-functional device that can perform punching, rough cutting, and finishing cutting operations in sequence. This universal tool replaces multiple specialized machines, simplifying the manufacturing system while maintaining the precision benefits of each individual operation
2Manufacturing precision
If multiple special processing machines are used for sequential operations, then the manufacturing precision is improved, but the productivity decreases due to multiple clamping and positioning steps
Solution Approach 1:
The patent merges multiple operations (punching, rough cutting, finishing cutting) into a single machining tool that performs all operations in one clamping position. This eliminates the need for multiple clamping and positioning steps, significantly improving productivity while maintaining the precision of each operation through sequential execution within the same tool
3Productivity
If a single machining tool performs all operations, then the productivity and ease of manufacture are improved, but the manufacturing precision may be compromised
Solution Approach 1:
The machining tool is segmented into distinct functional portions: a punching tool portion, a rough cutting tool portion, and a finishing cutting tool portion. Each portion is optimized for its specific function, with the finishing cutting tool portion having precise cutting edges for high-precision work. This segmentation allows the single tool to maintain high precision across all operations while improving productivity
Solution Approach 2:
Different portions of the machining tool have different local qualities optimized for their specific functions. The finishing cutting tool portion has highly precise cutting edges for final dimensional accuracy, while the rough cutting tool portion is designed for material removal. This local optimization ensures high precision is achieved where needed while maintaining overall productivity
Data Source
AI summary
A machine tool includes a fixed pillar, a finishing cutting tool with a first teeth portion, a rough cutting tool with a second teeth portion, a punching tool with a third teeth portion, and a support member passing through the punching tool, the rough cutting tool, and the finishing cutting tool and detachably mounted to the fixed pillar. The finishing cutting tool, the rough cutting tool, and the punching tool are arranged sequentially in a direction away from the fixed pillar. The outer diameter of the fixed pillar is smaller than the diameter of the finishing cutting tool. The diameter of the finishing cutting tool is greater than the diameter of the rough cutting tool. The diameter of the rough cutting tool is greater than the diameter of the punching tool. The present invention further provides a method of machining a box-end wrench by using the aforesaid machining tool.