Disc Milling Roughening Tool for Stable One-Pass Bore Microgrooving
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Solution Overview
Problem
Existing roughening tools for cylindrical surfaces in metal workpieces, such as piston running surfaces in internal combustion engines, face challenges in efficiently creating a defined microstructure with high vibration rigidity and stability, ease of assembly, and productivity, particularly when producing a large number of circumferential grooves with precise reproducibility.
Innovation Solution
A roughening tool with a tool body and disc milling cutters, each having a large number of cutting elements with a filigree toothing, arranged at equal angular intervals, allowing for simultaneous cutting of multiple microgrooves in a single machining step, with a design that enhances vibration rigidity and stability, simplifies assembly, and ensures reproducible accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a large number of filigree saw blades are arranged on the roughening tool to machine the entire cylindrical surface in one pass, then productivity is improved, but the tool becomes prone to vibrations and difficult to assemble
Solution Approach 1:
The cutting tools are segmented into multiple disc milling cutters arranged axially along the tool body. Each disc milling cutter contains multiple cutting elements with filigree toothing, allowing the tool to machine multiple circumferential grooves simultaneously while maintaining structural rigidity through the distributed modular architecture
Solution Approach 2:
Multiple cutting elements are combined on each disc milling cutter, with each cutting element having filigree toothing that produces multiple circumferential grooves. This merging approach concentrates the groove-producing capability into fewer, more robust cutting units rather than using many individual filigree saw blades
2Productivity
If a large number of filigree saw blades are arranged on the roughening tool to machine the entire cylindrical surface in one pass, then productivity is improved, but the assembly process becomes time-consuming and complex
Solution Approach 1:
The cutting tools are segmented into multiple disc milling cutters arranged axially along the tool body. Each disc milling cutter contains multiple cutting elements with filigree toothing, allowing the tool to machine multiple circumferential grooves simultaneously while maintaining structural rigidity through the distributed modular architecture
Solution Approach 2:
Each disc milling cutter serves as a universal cutting unit that can be identically manufactured and assembled at different axial positions. This standardization simplifies the assembly process, as the same type of cutting tool is repeated along the tool body rather than requiring unique arrangement of many individual filigree saw blades
3Manufacturing precision
If several processing steps are used to introduce a predetermined number of circumferential grooves, then manufacturing precision is improved, but processing time increases
Solution Approach 1:
The roughening tool performs continuous useful action by machining the entire cylindrical surface in a single continuous operation. Multiple disc milling cutters with multiple cutting elements work simultaneously to produce all required circumferential grooves in one pass, eliminating the need for repeated axial movements and radial positioning operations
Solution Approach 2:
The tool is designed with all necessary cutting elements pre-positioned on the tool body before machining begins. The disc milling cutters are arranged axially with predetermined spacing, and each cutting element's filigree toothing is pre-configured to produce the exact groove pattern required, eliminating the need for multiple setup and positioning operations
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 tool achieves high productivity and reproducible accuracy in creating a microstructure with multiple circumferential grooves, reducing processing time and assembly complexity while maintaining tool stability and longevity.
Implementation Method 1
each having a large number of cutting elements with a filigree toothing... allowing for simultaneous cutting of multiple microgrooves
Data Source
Figure 1~2
Figure 3a
Figure 3b
AI summary
The invention relates to a roughening tool (1) for roughening the cylindrical surface of a bore in an in particular metal workpiece, for example the piston bearing surface of a cylinder bore or cylinder sleeve in an internal combustion engine, by producing a defined microstructure made up of a plurality of microgrooves extending circumferentially at an axial distance from each other. The roughening tool (1) has a main tool body (12) that can be driven so as to rotate about an axis of rotation (2) and a plurality of circumferentially cutting cutting tools arranged at a defined distance from each other on the main tool body (12). According to the invention, the cutting tools are each made up of a side milling cutter (21-33), and each side milling cutter (21-33) has at least one cutting element (21b-33b) that has a plurality of cutting teeth arranged at an axial distance from each other. In addition, the invention relates to a method for roughening a cylindrical surface.