Grooving Tool with Peening Flanks for Cylinder Wall Texturing
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Solution Overview
Problem
Existing surface roughening techniques for engine bores require multiple tools and incur additional costs and processing steps, which are inefficient and costly.
Innovation Solution
A grooving tool with a body and inserts featuring a cutting edge and a peening surface is used to form grooves and deform the upper edges of the grooves, reducing tool deflection and improving adhesion of metallic coatings through a single tool process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a cutting tool and a swiping tool are used separately for grooving and peening, then the grooves can be formed and peened, but additional tooling cost and processing steps are incurred
Solution Approach 1:
The patent combines the cutting tool and swiping tool into a single integrated grooving tool. The tool body includes both a cutting edge for forming grooves and a peening surface for deforming the upper edges of the grooves, eliminating the need for separate tools and reducing tooling complexity while maintaining coating adhesion strength
Solution Approach 2:
The grooving tool is designed with multi-functionality, performing both cutting and peening operations in one tool. The cutting edge creates the grooves while the peening surface simultaneously or sequentially deforms the groove edges, making the tool universal for both operations that previously required different specialized tools
2Reliability
If a cutting tool and a swiping tool are used separately, then the grooves can be formed and peened, but additional processing cost and process steps are incurred
Solution Approach 1:
By merging the grooving and peening functions into one tool, the number of process steps is reduced. The tool can perform both operations in a single machining pass or sequentially without tool changes, improving productivity while achieving the same wear resistance enhancement through groove formation and peening
3Device complexity
If the peening surface is close to the cutting edge, then the tool structure is compact, but tool deflection increases
Solution Approach 1:
The peening surface is positioned in a different spatial arrangement relative to the cutting edge, extending in the opposite rotational direction rather than being directly adjacent. This dimensional separation reduces tool deflection while maintaining a relatively compact overall tool structure through optimized geometry
4Productivity
If the grooving tool rotates in one direction for cutting, then the grooves are formed, but the peening surface cannot engage the workpiece
Solution Approach 1:
The tool is designed to rotate in different directions depending on the operation required. The cutting edge engages when rotating in one direction to form grooves, while the peening surface engages when rotating in the opposite direction, providing dynamic adaptability to different operational requirements
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 solution enhances the adhesion strength of metallic coatings, reduces tooling costs, and simplifies the machining process by integrating peening into the grooving tool, achieving higher operational speeds and improved wear resistance.
Implementation Method 1
a peening surface extending in the opposite rotational direction from the cutting edge for deforming the upper edges of the grooves when rotated in an opposite rotational direction
Implementation Method 2
The peening surface may have a coating with a lower coefficient of friction as compared to the coefficient of friction of the cutting edge
Data Source
AI summary
According to one aspect of this disclosure, a grooving tool is provided. The grooving tool has a body with a plurality of recesses. Plural inserts assembled into each of the recesses. The recesses include a cutting edge for forming grooves in an engine cylinder wall when rotated in one rotational direction. The insert also includes a peening surface extending in the opposite rotational direction from the cutting edge for deforming the upper edges of the grooves when rotated in an opposite rotational direction.