Impact Gun Drill Shank Sintering for High Torque and Coaxiality
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Solution Overview
Problem
Current drill shanks for IMPACT gun drills fail to meet standards for torque, impact strength, and radial runout, particularly the high-torque shank, which is costly and difficult to manufacture, and lacks sufficient manufacturing efficiency and cost-effectiveness.
Innovation Solution
A novel drill shank preparation process using a powder pressing, electric spark forming, and sintering method with a 2Cr25Ni20 forming block and metal powder mixture of 40% iron and 0.5-0.6% adsorbing agent, forming a non-cylinder cavity with planes for improved torque and assembly, and using a graphene adsorbing agent for enhanced strength and toughness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional drill shanks (stamping, pin, zinc alloy, taper) are used, then manufacturing cost is low, but torque and impact strength do not meet standards
Solution Approach 1:
The patent uses a composite material system consisting of tin bronze powder (63Sn70Cu), iron powder (40%), and adsorbing agent (0.5-0.6%), which combines the advantages of different materials to achieve both high strength/toughness and manufacturability. The composite powder mixture is formed into a green compact and then sintered to create the drill shank with required mechanical properties.
Solution Approach 2:
The patent optimizes multiple parameters including powder composition ratios (40% iron powder, 0.5-0.6% adsorbing agent), sintering temperature (1050-1150°C), and sintering time (15-25 minutes) to achieve the desired balance between strength, toughness, and manufacturing efficiency. These parameter changes enable the drill shank to meet torque and impact strength standards while maintaining ease of manufacture.
2Strength
If high-torque shank with non-cylinder cavity is used, then torque transmission is improved, but manufacturing procedures increase to 13-14 steps
Solution Approach 1:
The non-cylinder cavity with planes is pre-formed in the mold during the green compacting stage, before sintering. This preliminary formation of the complex internal structure eliminates the need for subsequent complex machining operations, reducing manufacturing steps while maintaining the torque transmission performance required for high-torque applications.
Solution Approach 2:
The patent combines multiple manufacturing operations into a single sintering process. The mold cavity, internal non-cylinder structure, and external dimensions are all formed simultaneously during green compacting and then consolidated in one sintering step, merging what would traditionally require multiple separate manufacturing procedures into an integrated process.
3Reliability
If integral shank is used, then performance meets standards, but manufacturing cost increases and coaxiality is difficult to achieve
Solution Approach 1:
The patent replaces traditional mechanical machining methods with a powder metallurgy forming and sintering system. The mold-based green compacting and sintering process inherently ensures coaxiality through the mold geometry, eliminating the need for complex mechanical alignment and machining operations required for integral shanks, while maintaining performance stability.
4Ease of manufacture
If zinc alloy shank is used, then manufacturing is simple, but deformation occurs and impact strength is insufficient
Solution Approach 1:
The patent replaces pure zinc alloy with a composite powder mixture of tin bronze, iron powder, and adsorbing agent. This composite material system provides superior impact strength and deformation resistance compared to zinc alloy, while maintaining manufacturing simplicity through the powder metallurgy process, which is equally straightforward but produces higher performance material.
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 process results in a drill shank with improved strength, toughness, and torque transmission, reducing manufacturing costs and increasing efficiency, with a service life 1-2 times longer than zinc alloy shanks and precise matching with drill bits.
Implementation Method 1
performing sintering densification to obtain a finished product
Implementation Method 2
0.5-0.6% of an adsorbing agent are added into tin bronze powder
Data Source
AI summary
A preparation process of a novel drill shank for an IMPACT gun drill, including: manufacturing a mold and a forming block, wherein a forming blind hole is formed in a middle of the mold, the forming block is inserted into the forming blind hole, a wire pipe is disposed in the mold, a feed port is formed in the forming block, a heating cavity is formed in a forming block lateral face and a forming post; manufacturing the forming block with a 2Cr25Ni20 material; injecting tin bronze powder and iron powder into the forming blind hole, starting vibration pressing by the forming block; inputting direct and pulse current to communicate with the metal powder and heat the metal powder at a same time; forming a drill shank blank after 2-3 min, taking out the drill shank blank; removing an adsorbing agent from the drill shank blank by an extraction method.