Forming Closed Longitudinal Grooves in Tool Shanks

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Solution Overview

Problem

Existing manufacturing methods for shanks of drilling, chiseling, or boring tools require machining steps to create closed longitudinal grooves for locking, which can be time-consuming and inefficient.

Innovation Solution

A method that forms closed longitudinal grooves without machining steps by using a die tool to shape the grooves, where the die tool engages in the groove with a shaped body that fills it form-fittingly, except for the open end section, and a further longitudinal groove is formed on the lateral surface, allowing material displacement to close the groove during compression.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If machining steps are used to create closed longitudinal grooves, then manufacturing precision can be achieved, but productivity decreases and manufacturing time increases

Engineering Contradiction:

Improveprecision of closed longitudinal groovesVSAvoidproduction efficiency of shanks

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The die tool is pre-shaped with the negative imprint of the desired longitudinal groove geometry. This preliminary preparation of the forming tool allows the groove shape to be transferred directly to the blank in one operation, eliminating the need for subsequent machining steps to achieve the final groove geometry.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces traditional mechanical machining operations (milling, turning) with a plastic deformation forming process. The die tool applies compressive force to plastically deform the blank material, directly forming the closed longitudinal grooves through material displacement rather than material removal, thereby eliminating machining steps.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If machining steps are used to create closed longitudinal grooves, then groove geometry can be achieved, but loss of time occurs

Engineering Contradiction:

Improvegeometry of longitudinal groovesVSAvoidmanufacturing cycle time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent combines multiple operations into a single forming step. The die tool simultaneously creates the longitudinal groove shape and closes the groove ends through plastic deformation in one continuous action, merging what would traditionally require separate machining operations into a single integrated process step.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The die tool is pre-configured with the exact groove geometry required, allowing the final groove shape to be formed directly during the forming operation without subsequent machining. This preliminary preparation of the tool geometry eliminates the time loss associated with multiple processing steps.

Inventive Principle:

Principle #10Preliminary action

3Manufacturing precision

If material is removed by machining, then groove shape can be created, but loss of substance occurs

Engineering Contradiction:

Improveshape of longitudinal groovesVSAvoidmaterial waste from blank

Core Design Contradiction:

Manufacturing precisionVSLoss of substance

Solution Approach 1:

The patent replaces material removal machining with plastic deformation forming. The die tool displaces material radially to close the groove ends, preserving all blank material within the formed structure. This substitution eliminates material waste by transforming the material's shape and position rather than removing it.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The forming process recovers all material from the blank by redistributing it within the formed structure. The plastic deformation process ensures that no material is discarded but rather repositioned to create the closed groove geometry, achieving near 100% material utilization.

Inventive Principle:

Principle #34Discarding and recovering

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

Enables the production of shanks with closed longitudinal grooves efficiently, eliminating the need for machining steps and ensuring secure locking without material loss, while maintaining the solid shape of the blank.

Implementation Method 1

when compressing the free, relatively large end face in the axial direction... sufficient material of the end piece can be displaced in the radial direction to close the longitudinal groove

Methodology Applied

Scientific EffectPlastic deformation: Plasticity

Data Source

PatentEP2361702B1Method for producing an insertion end

Publication Date: 2017.03.08 HILTI AG

AI summary

The method involves forming a longitudinal groove (27) into an outer surface (26') of an end part (26) of a blank (14). The groove is formed with an open end portion (30) at a face surface (29) of the end part. The outer surface of the end part is enclosed with a die tool, which engages into the longitudinal groove outside of open end portion by a mold body. The open end portion is closed by compressing the end part by a stamper, which effects on the face surface. Another longitudinal groove (28) is formed at the face surface into the outer surface.