Integrated Drill Geometry for Accurate Hole Deburring
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Solution Overview
Problem
In the context of drilling holes for airplane fasteners, existing methods face inefficiencies and accuracy issues due to excessive processing during deburring, which can result in holes that fail to meet stringent requirements, especially when forming over 1000 holes.
Innovation Solution
A drill with a main cutting edge for drilling and a deburring portion with a smaller angle and similar diameter to the main cutting edge for precise burr removal, along with a rotation speed varying unit to differentiate drilling and deburring speeds, preventing over-processing and damage to the holes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual burr removal is used, then burr removal is achieved, but productivity is low due to time consumption
Solution Approach 1:
The patent combines the drilling function and deburring function into a single integrated drill tool. The main cutting edge performs drilling while the deburring cutting edge, positioned adjacent to it, performs burr removal in one continuous operation, eliminating the need for separate manual deburring steps and significantly improving productivity
Solution Approach 2:
The drill tool is designed with multi-functionality, serving both as a drilling tool and a deburring tool. By integrating multiple cutting edges with different functions on a single tool body, the system achieves universal application for both hole creation and burr removal, reducing tool changes and operational time
2Productivity
If excessive processing is applied during deburring, then burr removal is achieved, but hole shape accuracy deteriorates
Solution Approach 1:
The deburring cutting edge is designed with locally optimized properties - a smaller angle relative to the central axis compared to the main cutting edge. This local differentiation allows the deburring portion to effectively remove burrs while the smaller angle prevents excessive material removal that would compromise hole shape accuracy
Solution Approach 2:
The patent applies partial action by using a deburring cutting edge with reduced aggressiveness (smaller angle) compared to the main cutting edge. This partial action is sufficient for burr removal without being excessive enough to damage the hole geometry, achieving the right balance between deburring effectiveness and precision maintenance
3Productivity
If deburring cutting edge has larger angle, then deburring effectiveness is improved, but hole damage risk increases
Solution Approach 1:
The patent changes the geometric parameter (angle) of the deburring cutting edge relative to the central axis, making it smaller than the main cutting edge angle. This parameter modification optimizes the balance between deburring effectiveness and hole protection, ensuring reliable hole integrity while maintaining burr removal capability
Data Source
AI summary
Provided is a drill that can drill with good accuracy without over-processing during deburring. The drill includes: a drill main body that is rotated around a central axis; a main cutting edge provided at a leading end of the drill main body; and a deburring cutting edge that is provided on a base end side of the drill main body, adjacent to the main cutting edge, and performs deburring. The deburring cutting edge is similar in diameter to the main cutting edge and has an angle (β) smaller than an angle (α) formed by the main cutting edge relative to the central axis.