Hexagonal Drill Shank Molding With Hollow Cavity for High Torque
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Solution Overview
Problem
Existing high-torque drill shanks are costly and complex to produce, with the one-piece shank being the only type that meets performance standards but requiring 13-14 processes, while others fail to meet torsion and impact strength requirements.
Innovation Solution
A method for manufacturing a high-torque hexagonal drill shank using powder injection molding with a hollow air module, high-pressure air, and a specific binder composition to form a non-cylindrical cavity, reducing production processes and costs, and achieving high torque and precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a one-piece shank is used to meet torque and impact strength standards, then mechanical performance is improved, but manufacturing complexity and cost increase significantly due to requiring 13-14 different processes
Solution Approach 1:
The drill shank is divided into multiple components: a cylindrical body portion and a separate non-cylindrical cavity portion. The non-cylindrical cavity is formed as a distinct feature within the body, allowing independent manufacturing and assembly. This segmentation reduces the overall manufacturing complexity from 13-14 processes to a fewer number of steps while maintaining the required mechanical strength through proper material selection and cavity design.
Solution Approach 2:
The non-cylindrical cavity is provided with a plane on its lateral side, and the corresponding drill bit shank portion also has a plane. These localized planar features are specifically designed to fit together with adhesive, creating a tight fit that ensures high torque transmission and high punching accuracy. This local quality approach allows the majority of the shank to be manufactured using simpler processes while only requiring precise machining at specific locations.
2Strength
If a high-torque shank with non-cylindrical cavity is used to achieve high torque and punching accuracy, then mechanical performance is improved, but manufacturing complexity increases compared to simpler shank types
Solution Approach 1:
The non-cylindrical cavity is pre-formed within the drill shank body during the manufacturing process, rather than being created through multiple subsequent machining operations. The cavity is designed with a plane on its lateral side that corresponds to a plane on the drill bit shank portion, allowing for preliminary preparation of fitting surfaces that simplify final assembly and ensure high torque transmission without requiring excessive post-processing.
3Ease of manufacture
If simpler shank types like punch shank, pin shank, zinc alloy shank, or taper shank are used, then manufacturing is easier and cost is lower, but they fail to meet torsion and impact strength standards
Solution Approach 1:
The drill shank utilizes a composite structure combining a cylindrical body portion with a non-cylindrical cavity portion. The non-cylindrical cavity is designed with specific geometric features including a plane on its lateral side, which fits with a corresponding plane on the drill bit shank. This composite design allows the use of materials and processes that are easier and more cost-effective than solid one-piece construction, while the interlocking cavity structure provides the necessary torsion and impact strength that simpler shank types cannot achieve.
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 method results in a high-torque hexagonal drill shank with low processing costs, high precision, and superior mechanical performance, meeting torque and impact strength standards with fewer production steps.
Implementation Method 1
high-pressure air of 150-180 bar is injected into the air module
Implementation Method 2
injecting obtained particulates in a heating-plasticizing state into the molding cavity by an injection molding machine to solidify to form a hexagonal drill shank blank, wherein an injection pressure is 140 bar
Implementation Method 3
removing the binder in the hexagonal drill shank blank by thermal decomposition
Implementation Method 4
finally, obtaining a high-torque hexagonal drill shank by sintering and densifying, wherein a sintering temperature is 800-1200° C.
Data Source
AI summary
A method for manufacturing a high-torque hexagonal drill shank includes: firstly producing an air module, wherein the lower end of the air module is inserted into a molding cavity of a mold, a high-pressure air is injected into the air module, and the surface of the air module is provided with a plurality of air outlets; evenly mixing metal powder and an organic binder together; injecting obtained particulates in a heating-plasticizing state into the molding cavity by an injection molding machine to solidify and form a hexagonal drill shank blank; forming a non-cylindrical cavity inside the hexagonal drill shank blank under the action of the air module; removing the binder in the hexagonal drill shank blank by thermal decomposition; and, finally, obtaining a high-torque hexagonal drill shank by sintering and densifying.