Combined Honing and Deburring Tool for Complete Bore Burr Removal
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Solution Overview
Problem
Existing combination tools for honing and deburring bores, particularly in connecting rod eyes, face challenges with burr removal efficiency and cycle time optimization, often resulting in incomplete deburring and prolonged processing times.
Innovation Solution
A combination tool with an elongated body featuring a honing section and an axially offset deburring section, where cutting segments are radially movable and resiliently mounted, allowing for adjustable effective diameter and uniform deburring across the circumference, along with a multi-stage machining process that separates deburring into distinct stages for improved efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate deburring tool and tool change process is used, then deburring can be performed, but cycle time increases and productivity decreases
Solution Approach 1:
The patent combines the honing tool and deburring tool into a single integrated combination tool. The honing section with honing stones and the deburring section with cutting segments are mounted on the same tool body, allowing both honing and deburring operations to be performed without tool changes. This merging of functions directly resolves the contradiction by eliminating tool change time while maintaining complete burr removal capability.
Solution Approach 2:
The combination tool is designed with multi-functionality, serving both as a honing tool and a deburring tool. The tool body accommodates both honing stones for surface finishing and cutting segments for burr removal, enabling a single tool to perform multiple machining functions. This universality eliminates the need for separate tools and tool changes, thereby reducing cycle time while ensuring reliable deburring.
2Ease of manufacture
If a fixed deburring tool design is used, then manufacturing is simple, but adaptability to different bore sizes and positions is limited
Solution Approach 1:
The cutting segments in the deburring section are designed to be radially adjustable rather than fixed. The segments can be moved radially inward or outward to adapt to different bore diameters and positions. This dynamic adjustability allows the same tool to work on various connecting rod eye sizes and bore positions without compromising manufacturing simplicity, as the adjustment mechanism integrates into the existing tool structure.
Solution Approach 2:
The tool enables parameter changes by allowing radial adjustment of the cutting segments. The effective diameter of the deburring section can be modified by changing the radial position of the cutting segments, accommodating different bore sizes. This parameter adjustability maintains ease of manufacture while significantly improving versatility for different workpiece configurations.
3Manufacturing precision
If multiple tool changes are performed for honing and deburring, then each operation can be optimized, but time loss increases
Solution Approach 1:
The patent merges the honing tool and deburring tool into a single combination tool, eliminating the need for tool changes between honing and deburring operations. The tool body simultaneously accommodates both honing stones and cutting segments, allowing sequential performance of both operations without interrupting the machining process. This directly addresses the time loss issue while maintaining the manufacturing precision of both operations.
Solution Approach 2:
The combination tool enables continuous useful action by performing honing and deburring in sequence without tool changes. The honing section and deburring section work in a coordinated manner, with the honing stones preparing the surface and the cutting segments immediately following to remove burrs. This continuity eliminates idle tool change time while preserving the quality benefits of dedicated honing and deburring operations.
4Productivity
If a complex combination tool design is used to integrate honing and deburring, then productivity improves, but device complexity and manufacturing cost increase
Solution Approach 1:
The combination tool uses segmentation to manage complexity by dividing the tool body into distinct functional sections. The honing section with multiple honing stones and the deburring section with cutting segments are separated into independent modules mounted on the same tool body. This segmentation allows each section to be designed and manufactured independently, simplifying the overall construction while maintaining the productivity benefits of integration.
Solution Approach 2:
The tool applies local quality by providing specialized functions at specific locations along the tool body. The honing stones are positioned in the honing section for surface finishing, while the cutting segments are positioned in the deburring section for burr removal. Each section has optimized local characteristics for its specific function, managing overall device complexity through localized specialization rather than requiring the entire tool to be overly complex.
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
The solution enables reliable, efficient, and cost-effective honing and deburring with reduced cycle times, ensuring complete burr removal and improved surface quality without the need for extensive tool changes, thereby enhancing the processing of connecting rod eyes and other cylindrical components.
Implementation Method 1
At least one cutting segment is arranged in the deburring section, which is individually movable and spring-mounted radially to the tool axis... the cutting segment derives its machining force when removing a burr from, among other things, the spring force of the spring-loaded mounting
Implementation Method 2
The honing stone units each have at least one abrasive cutting layer on their outer sides with cutting grains bonded in a bond
Data Source
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AI summary
A combination tool for honing and deburring a bore, in particular for honing and deburring a connecting rod eye in a connecting rod, comprises a tool body (110) defining a tool axis (112), coupling structures (120) for connecting the tool body to a work spindle or a drive element of a machine tool, wherein the coupling structures are arranged at a spindle-side end of the tool body (110), a guide opening extending in the tool body (110) parallel to the tool axis (112) for receiving and guiding a feed element displaceable parallel to the tool axis (112), and a honing section (130) with several openings extending radially from the guide opening to the tool axis (112) for receiving a honing stone unit (180) each.which is operatively connected to the feed element (190) and can be adjusted radially to the tool axis (112) by axial displacement of the feed element (190). Furthermore, at least one deburring section (200) is provided, arranged axially offset from the honing section, in which one cutting segment or several cutting segments (220) distributed around the circumference of the combination tool are arranged, wherein one cutting segment is individually movable and spring-mounted radially to the tool axis (112). In the deburring section (200), an individual receiving pocket (230) with a bottom surface (255) facing the guide opening (114) and side surfaces (222) is formed in the tool body (110) for each cutting segment. Each of the cutting segments is received in an individual receiving pocket (230) in the tool body (110).