Hollow Abrasive Tool Head for Deep Glass Recesses
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Solution Overview
Problem
Existing rotary machining tools face challenges in producing deep holes and milled recesses in hard and brittle materials like glass and glass ceramics without causing breakage or material strength reduction, due to tool shank instability and risk of crack formation.
Innovation Solution
A rotary tool head with a hollow cylindrical abrasive body and central abrasive area connected by webs, allowing for efficient grinding and drilling with a geometrically undefined cutting edge, which maximizes tool head diameter relative to recess size and minimizes lateral movement for smooth material removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional drills with cemented carbide cutting edges are used, then drilling capability is achieved, but crack formation and material strength reduction occur in hard and brittle materials
Solution Approach 1:
The patent replaces conventional mechanical drilling with a grinding process using a rotary tool head equipped with abrasive bodies. Instead of using a cemented carbide cutting edge that causes cracking, the invention uses abrasive grinding surfaces that progressively remove material through friction and abrasion, eliminating the shock loads and crack formation associated with traditional drilling while maintaining manufacturing capability.
2Length of moving object
If deep holes are produced using conventional tools, then hole depth is achieved, but tool shank instability and breakage risk increase
Solution Approach 1:
The patent employs a hollow cylindrical abrasive body with a thin-walled structure that maintains stability during deep hole machining. The hollow design reduces the tool's overall weight and moment of inertia, improving stability during rotation and material removal, while the distributed abrasive surfaces on the cylindrical body provide balanced cutting forces that prevent shank deflection and breakage even at great depths.
3Productivity
If tools with small diameter relative to recess size are used, then material removal efficiency is maintained, but tool head diameter is limited by shank stability
Solution Approach 1:
The patent transitions from conventional end-mill or drill geometries to a rotary tool head with abrasive bodies distributed around the cylindrical perimeter. This dimensional change allows the cutting action to occur along the entire circumference of the tool head, dramatically increasing material removal efficiency while maintaining a compact tool head diameter that preserves shank stability. The grinding action occurs radially outward from the cylindrical surface, maximizing productivity without increasing tool diameter.
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
Enables the production of deep recesses with a minimum radius of 6 mm and depth-to-radius ratio greater than 10:1 in glass and glass ceramics, reducing material strength loss and ensuring smooth, vibration-free walls, suitable for lightweight structures like telescope mirror supports.
Implementation Method 1
a hollow cylindrical abrasive body that merges into a preferably hollow shank, wherein a central abrasive area is arranged at an end face of the hollow cylindrical abrasive body
Data Source
AI summary
A tool head capable of introducing deep recesses into hard and brittle material such as glass and glass ceramics is provided. The tool head includes a hollow cylindrical abrasive body merging into a hollow shank. The hollow cylindrical abrasive body has an end face with a central abrasive area at the location of a cylinder axis. The central abrasive area is connected with the inner wall surface of the hollow cylindrical abrasive body by at least one web. The end face of the abrasive body, the web, and at least a portion of the outer wall surface of the abrasive body are covered with abrasive. The hollow shank has at least one opening to the interior between the at least one web and the inner wall surface of the abrasive body.