Machining Tool Insert Holder Compression Design
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Solution Overview
Problem
Existing machining tools face high costs due to expensive methods like brazing and press fitting, which are difficult and require precise tolerances, to secure insert tips to holders.
Innovation Solution
A machining tool design featuring an insert holder with elevated projections that are compressed to secure insert tips, allowing for larger tolerances and using a less expensive material like sintered powder metal, with increased-density features to securely hold harder insert tips like cubic boron nitride.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If brazing is used to connect insert tips to insert holders, then sufficient holding forces are achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent replaces the thermal joining process (brazing) with a mechanical compression system. A compression device applies axial compressive force to the insert holder, which transmits the force through the insert tip slot to secure the insert tip. This mechanical substitution eliminates the complexity of brazing operations while achieving sufficient holding forces through direct compression.
2Strength
If press fitting is used to connect insert tips to insert holders, then holding forces are achieved, but manufacturing precision requirements increase
Solution Approach 1:
The patent introduces a dynamic compression system that applies controlled axial force during assembly. Rather than relying on static interference fit with tight tolerances, the compression device dynamically adjusts and applies force to secure the insert tip, allowing for larger tolerances while maintaining adequate holding forces.
3Ease of manufacture
If compression method is used to secure insert tips, then manufacturing cost is reduced, but attachment security must be maintained
Solution Approach 1:
The patent incorporates preliminary positioning features in the insert holder that guide and pre-position the insert tip before compression is applied. This preliminary action ensures proper alignment and placement, and the subsequent compression secures the tip reliably. This two-stage approach maintains attachment security while using the simpler, less expensive compression method.
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
This approach reduces manufacturing costs by enabling secure attachment with simpler compression methods and larger tolerances, resulting in cost-effective machining tools while maintaining performance.
Implementation Method 1
compressing the insert holder to thereby secure the first cutting insert tip within the first insert tip slot
Data Source
AI summary
A method of manufacturing a machining tool in which an insert holder comprises a first surface, a second surface opposite the first surface, and a first insert tip slot extending between the first surface and the second surface. The first insert tip slot is configured so as to be compressed and densified to support a first insert tip. The insert holder further includes elevated projections extending from the first and second surfaces proximate the first insert tip slot.