Friction-Welded Drill Insert Tool for Simpler Manufacturing
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Solution Overview
Problem
The manufacturing process of drilling tools is complex and expensive due to the multiple steps involved in adapting the shank, producing the conveyor helix, connecting and grinding the drill head, and coloring the tool.
Innovation Solution
A base module with a conveyor helix and a cutting body is integrally bonded to a hardened shank using friction welding, allowing for a simpler manufacturing process and individualization of the drilling tool with a cutting element design and surface marking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional multi-step manufacturing process is used for drilling tools, then complete functional requirements are met, but manufacturing complexity and cost increase
Solution Approach 1:
The drilling tool is divided into modular components: a base module containing the conveyor helix and a separate cutting body. This segmentation allows independent manufacturing of components that can be joined through friction welding, simplifying the overall manufacturing process while maintaining functional completeness.
Solution Approach 2:
The base module integrates the conveyor helix and cutting body into a unified structure through friction welding. This merging of components reduces the number of separate manufacturing steps and assembly operations, thereby reducing manufacturing complexity and cost.
2Ease of manufacture
If traditional manufacturing process is used, then all functional requirements are satisfied, but production cost increases
Solution Approach 1:
By segmenting the tool into a base module and cutting body, each component can be manufactured using optimized processes for its specific requirements. The base module can be produced with standard precision while the cutting body receives specialized attention, reducing overall manufacturing cost without compromising tool quality.
Solution Approach 2:
The friction welding process enables controlled joining of components with specific hardness requirements. The base module can be hardened to 48-56 HRC while the cutting body maintains higher hardness, achieving the required manufacturing precision through parameter control during the joining process.
3Adaptability or versatility
If a unified drilling tool design is used, then manufacturing is simpler, but adaptability to different applications is reduced
Solution Approach 1:
The base module serves as a universal component that can be combined with different cutting bodies for various applications (rock drilling, metal drilling, tile drilling, wood drilling). This multi-functionality approach allows a single base module design to support multiple tool types, enhancing adaptability without increasing design complexity.
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 approach reduces manufacturing complexity and cost by enabling the production of various drilling tools, such as rock, metal, and tile drills, while providing a method for surface marking to indicate wear and optimal operating parameters.
Implementation Method 1
The shank is hardened before connection to the base module. The hardening process required for this is carried out in particular by means of an oven
Implementation Method 2
the base module is connected at a second end to an in particular hardened shank in a cohesive manner, in particular by means of a friction welding process
Data Source
Figure 1
Figure 2a~2b
Figure 2c~2d
AI summary
The invention relates to an insert tool, in particular a drilling tool, with a base module, wherein the base module comprises a first section, in particular a feed spiral, and a cutting body, preferably comprising at least two rake faces, and wherein the second section is metallurgically connected to a first end of the first section. It is proposed that the base module be metallurgically connected at a second end to a stub end, in particular a hardened stub end, preferably by a friction welding process.