Custom Shaped Blank for Matrix Drill Bit Webbing Elimination
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Solution Overview
Problem
Traditional drill bit manufacturing methods result in webbing, a triangular piece of material left between blades, which is time-consuming and costly to remove, posing safety risks and compromising the integrity of the matrix bit.
Innovation Solution
A custom-shaped blank with a tang section, angled section, and base section that engages a former with recesses to reduce or eliminate webbing, featuring optimized dimensions and radial grooves for improved mechanical bonding and reduced crack propagation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional axial-symmetrical blank designs are used with constant dimensions, then manufacturing simplicity is maintained, but webbing is formed in the junk slot area requiring costly post-processing
Solution Approach 1:
The patent applies asymmetry by transitioning from traditional axial-symmetrical blank designs to custom-shaped blanks with non-uniform dimensions. The blank features variable outer diameters, inner diameters, tang lengths, and angles that are specifically optimized for each position to eliminate webbing formation in the junk slot area while maintaining manufacturing feasibility through controlled variation rather than complete irregularity
Solution Approach 2:
The patent implements local quality by applying different dimensional characteristics to different regions of the blank. Specifically, the tang section has optimized length and angle, the angled section has specific taper ratios, and the base section has tailored outer and inner diameters. Each section's dimensions are locally optimized to prevent webbing in critical areas while maintaining overall structural integrity
2Shape
If junk slot sand is added to the mold assembly to create junk slots, then blade separation is achieved, but webbing is created between blades requiring time-consuming grinding removal
Solution Approach 1:
The patent applies preliminary action by pre-shaping the blank with custom dimensions before molding to anticipate and prevent webbing formation. The blank is designed with variable tang length, angled section dimensions, and base section geometry that proactively eliminates the conditions for webbing creation, eliminating the need for subsequent grinding removal operations
Solution Approach 2:
The patent extracts the webbing problem by removing the conditions that create it through custom blank shaping. By optimizing the blank's tang section, angled section, and base section dimensions, the design eliminates the triangular material accumulation between blades, effectively taking out the webbing issue before it can form during the molding process
3Manufacturing precision
If webbing is ground away from the matrix bit, then surface quality is improved, but production cost increases and potential damage to the bit occurs
Solution Approach 1:
The patent applies preliminary anti-action by designing the blank with custom-shaped dimensions that prevent webbing formation in the first place. The optimized tang length, angled section geometry, and base section dimensions create a mold cavity configuration that eliminates the conditions for webbing creation, thereby preventing the harmful effect before it occurs and avoiding the need for corrective grinding operations
Data Source
AI summary
A blank may include a tang section, a base section, and an angled section with a recess. The tang section may have an outer surface with an outer diameter. The base section may have an outer surface with a diameter greater than the outer diameter of the tang section. The angled section may lie between the tang section and the base section and may have an outer surface that transitions in diameter from the outer diameter of the tang section to the outer diameter of the base section. The recess in the angled section may be shaped to engage a tip of a former.