Drill Reamer Acute Cutting Edge Composite Materials
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Solution Overview
Problem
Traditional drill geometries, such as twist drills, are ineffective in machining fibre reinforced composites due to high forces causing heat generation, structural degradation, and material damage, while diamond incorporated dagger drills suffer from reduced productivity and tool longevity due to high load distribution on cutting edges.
Innovation Solution
A drill reamer with a combination of hard and soft cutting sections, featuring a tapered cutting edge with acute angles for initial penetration and subsequent precision cutting, utilizing polycrystalline diamond inserts for durability and carbide or tungsten carbide for stability, allowing for efficient drilling and reaming with reduced tool changes and increased production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional twist drill geometry with obtuse angle is used, then drilling capability is provided, but high forces are generated causing heat generation, structural degradation, and material damage
Solution Approach 1:
The patent changes the critical parameter of cutting edge angle from obtuse (traditional twist drill) to acute (dagger geometry). This parameter change reduces the forces generated during drilling, preventing heat generation and material damage while maintaining drilling capability in composite materials
Solution Approach 2:
The patent applies composite material principle by combining polycrystalline diamond inserts with a carbide or tungsten carbide body. This composite structure provides both the acute angle geometry for reduced forces and the hardness for cutting through abrasive composite materials without excessive wear
2Reliability
If diamond incorporated dagger drills are used, then tool life and hole quality are improved, but productivity is restricted due to high load on cutting edges
Solution Approach 1:
The patent segments the cutting edge into distinct zones: a tip region with high load capacity for initial penetration, and distal regions with diamond inserts for precision cutting and surface finish. This segmentation allows different portions of the cutting edge to perform different functions, distributing the workload and enabling higher productivity without sacrificing tool life or hole quality
Data Source
AI summary
A drill reamer (20) comprises an elongate body (21) disposed about a longitudinal axis. The elongate body comprises flutes (22a-22d) having separate hard cutting sections (27a, 28′a, 28″a, 28′b, 28″b) and a soft cutting section (24a, 24b). The soft cutting section is formed of a material such as carbide having a hardness that is less than that of the hard cutting sections, which may be formed of polycrystalline diamond. At least one first hard cutting section (27a) is axially displaced relative to at least one second hard cutting section (28′a, 28″a). The reamer has a tip cutting edge (23a, 23c) and tapered cutting edge portions (24a-24d) disposed at an acute angle relative to the longitudinal axis.