Composite Reamer Structure for Lower Weight and Inertia
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Heavy cutting tools, such as reamers, are cumbersome for operators due to their weight, leading to increased handling difficulties and reduced operational efficiency, and often exceed weight limits of automatic tool changers.
Innovation Solution
The use of additive manufacturing with composite materials like steel and carbon fiber to optimize the shape and distribution of material in cutting tools, reducing weight while maintaining strength and functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If traditional solid materials are used for large cutting tools, then strength and stiffness are maintained, but weight increases making the tool cumbersome and exceeding machine weight limits
Solution Approach 1:
The patent employs composite materials consisting of carbon fiber reinforced plastic (CFRP) combined with steel components. The CFRP arms provide lightweight structural support while steel cutting rings and connection members maintain cutting functionality and structural integrity. This composite approach reduces overall tool weight while preserving necessary strength and stiffness for cutting operations.
Solution Approach 2:
The patent applies different materials to different parts of the cutting tool based on local requirements. The arms supporting the cutting head are made of lightweight CFRP, while the cutting rings and connection members use steel for high strength. This localized material selection optimizes the weight-strength balance by placing heavy materials only where structurally necessary.
2Speed
If traditional solid materials are used for large cutting tools, then structural integrity is maintained, but moment of inertia increases reducing acceleration and deceleration speed
Solution Approach 1:
The CFRP arms provide sufficient structural integrity for supporting the cutting head while having significantly lower density than solid steel construction. This reduces the moment of inertia of the cutting tool, enabling faster acceleration and deceleration during operation, while the steel components maintain structural integrity at critical connection points.
3Ease of operation
If material distribution is optimized to reduce weight, then handling ease improves, but manufacturing complexity increases
Solution Approach 1:
The cutting tool is divided into separate modules: CFRP arms, steel cutting rings, center tube, and connection members. This segmentation allows each component to be manufactured independently using appropriate processes (composite layup for arms, machining for steel parts), then assembled together. This reduces manufacturing complexity compared to creating a monolithic optimized structure while achieving weight reduction for improved handling.
Data Source
AI summary
A lightweight cutting tool, such as a reamer, includes a front cutting body, a front cutting ring, a center tube, a rear cutting ring and a rear machine connection member. An arm assembly of the front and rear cutting heads includes one or more leading arms, one or more trailing arms and a cutting head supported by the leading and trailing arms. The leading arms and the trailing arms curve in opposite directions. To reduce weight and moment of inertia of the reamer, a cross-sectional area of the leading arms and the trailing arms is largest proximate the sleeve member and is smallest proximate the cutting head. In addition, the front cutting body, the front and rear cutting rings and the center tube may be made by additive manufacturing. Fluid can be transported entirely through the reamer to the cutting insert/workpiece interface and the guide pad/workpiece interface.