Solid Carbide Drill With Honeycomb Support Structure
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Solution Overview
Problem
Cutting tools, particularly solid carbide drills, face challenges in material efficiency and mechanical stability due to the need for central recesses which consume sintering material, and existing designs do not effectively distribute forces to minimize material usage while maintaining stability.
Innovation Solution
A cutting tool design featuring a base body with a support structure comprising multiple recesses separated by intersecting webs, which can be made of a softer material than the outer shell, providing a honeycomb-like or grid-like configuration to maximize material savings while ensuring mechanical stability through internal support and reduced outer shell thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If a single central recess is formed in the base body to save sintering material, then material usage is reduced, but the mechanical stability and force absorption capacity of the shaft deteriorates
Solution Approach 1:
The single central recess is divided into multiple smaller recesses separated by internal webs. This segmentation allows the recesses to be distributed throughout the base body, reducing material usage while the webs maintain structural integrity and force absorption capacity. The multiple recesses can be arranged to optimize both material savings and mechanical stability.
2Loss of substance
If the outer shell wall thickness is reduced to save material, then material usage decreases, but the mechanical stability and strength of the base body deteriorates
Solution Approach 1:
The base body is segmented into multiple compartments by internal webs, creating a cellular structure. This segmentation allows for thinner outer shell walls while the internal webs provide the necessary structural support and force absorption, effectively distributing mechanical loads throughout the structure.
Solution Approach 2:
The base body employs a porous or cellular internal structure with multiple recesses and webs. This porous configuration reduces material usage in the outer shell while the internal framework of webs maintains mechanical stability, allowing the structure to absorb forces efficiently despite reduced material thickness.
3Loss of substance
If multiple recesses are formed instead of a single central recess, then material savings increase, but the structural complexity and manufacturing difficulty increases
Solution Approach 1:
The support structure is segmented into multiple webs that divide the base body into separate compartments. While this creates multiple recesses for material savings, the webs are designed to be integrated into the sintering process, forming a unified structure that reduces manufacturing complexity compared to assembling separate components.
Solution Approach 2:
The internal webs serve multiple functions: they separate recesses to save material, provide structural support, and act as force transmission paths. This multi-functionality reduces the need for additional structural elements, simplifying the overall design and manufacturing process despite the increased number of recesses.
Data Source
AI summary
The cutting tool (1), especially drill or milling cutter, comprises a base (3) which extends in an axial direction (2) and has an outer shell (14) with at least one interior recess (18) that extends in the axial direction (2), a supporting structure (16) having at least one separating piece (26) which separates a plurality of recesses (18) from each other being formed in the supporting structure. The cutting tool (1) is particularly a solid hard-metal tool. The supporting structure (16) ensures an efficient use of material.