Dimple-Forming Burnishing Tool with Segmented Mandrel
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Solution Overview
Problem
Existing dimple-forming burnishing tools face challenges in adjusting dimple shape due to a polygonal mandrel cross-section, leading to unstable dimple formation and redundant dimple formation during tool retraction.
Innovation Solution
A dimple-forming burnishing tool with a mandrel featuring a dimple adjusting mechanism, comprising a rolling element rotating portion and a pressing element in-and-out rotating portion, prevents radial movement of the rolling element while allowing radial movement of the pressing element, enabling precise dimple shape adjustment and preventing redundant dimple formation during retraction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a polygonal cross-sectional mandrel is used for rotation, then the tool can be constructed with simple geometry, but the rollers and balls move radially in and out simultaneously causing unstable dimple formation and difficult adjustment of dimple shape
Solution Approach 1:
The mandrel surface is segmented into distinct functional zones: a first region with a polygonal cross-section that engages only the pressing elements (balls) to enable radial in-and-out movement for dimple formation, and a second region with a circular cross-section that engages only the rolling elements (rollers) to prevent their radial movement. This segmentation allows independent control of each element type, resolving the contradiction between simple mandrel geometry and precise dimple shape adjustment.
2Device complexity
If the tool diameter remains constant during retraction, then the tool structure is simple, but redundant dimples are formed on the workpiece surface during tool withdrawal
Solution Approach 1:
The tool is designed with dynamic diameter adjustment capability through a diameter adjustment mechanism that reduces the effective tool diameter during retraction. The pressing elements (balls) are configured to protrude radially during processing but retract when the tool is withdrawn, while the rolling elements (rollers) maintain constant contact. This dynamic adjustment prevents redundant dimple formation during tool withdrawal while maintaining simple overall tool structure.
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
This design allows for stable and precise dimple formation with easier adjustment of groove width, length, or depth, and prevents redundant dimple formation during tool retraction, enhancing the tool's operational efficiency and surface quality.
Implementation Method 1
burnishing is categorized in plastic deformation in which a work surface of a workpiece is crushed and deformed by rotating a hard roller while pressing the hard roller against the workpiece
Data Source
AI summary
A dimple-forming burnishing tool allowing easy adjustment of a dimple shape is provided. The dimple-forming burnishing tool has a mandrel attached on a rear-end side thereof to a processing machine for rotation, and a cylindrical frame rotatably externally fitted on a tip side of the mandrel and holding a rolling element and a pressing element that are driven by rotation of the mandrel, for forming dimples in an inner surface of a workpiece by rotating the mandrel with the frame disposed inside the inner surface of the workpiece. In the dimple-forming burnishing tool, the mandrel includes a dimple adjusting mechanism. The dimple adjusting mechanism includes: a rolling element rotating portion causing the rolling element to rotate without moving in and out radially of the frame; and a pressing element in-and-out rotating portion causing the pressing element to rotate while moving in and out radially of the frame.