Machining Tool System Weight Reduction via Composite Segmentation
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Solution Overview
Problem
Conventional cutting tool systems for machining cylindrical bores face challenges in reducing tool weight and tilting moment, which affect precision and accuracy, especially for long tool projections.
Innovation Solution
A cutting tool system featuring a cylindrical holding shank with a cutting head fixture and a tool coupling having elevated regions with bearing faces, where the cutting head and tool coupling are firmly connected using a joining material introduced into interspaces between these regions, allowing for a significant weight reduction and improved precision by preventing tilting and ensuring accurate alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional steel tool systems are used, then strength and reliability are maintained, but tool weight and tilting moment increase, reducing precision for long tool projections
Solution Approach 1:
The patent applies composite materials by combining a metal holding shank with a non-metallic cutting head (such as ceramic or carbide). This composite construction reduces the overall tool weight compared to conventional all-steel tools while maintaining the necessary strength and precision for accurate drilling, directly resolving the contradiction between weight reduction and precision maintenance.
2Manufacturing precision
If tool weight is reduced, then precision is improved, but connection strength between components may deteriorate
Solution Approach 1:
The tool system is segmented into distinct components (holding shank and cutting head) that can be optimized independently. The holding shank can be made lightweight while the cutting head maintains strength through material selection, and the connection interface is designed with specific geometric features to ensure strong bonding despite the lightweight construction.
Solution Approach 2:
Different parts of the tool system have different material properties optimized for their specific functions. The holding shank uses lightweight material for precision, while the cutting head uses hard, strong material for cutting performance, and the connection interface uses specialized geometry and joining methods to ensure strength at the critical bonding location.
3Manufacturing precision
If cutting head is firmly connected to holding shank, then alignment precision is maintained, but joining material may escape during operation
Solution Approach 1:
The connection interface is pre-designed with retaining features (such as recesses or barriers) that prevent joining material escape before operation begins. This preliminary structural arrangement ensures that during high-speed drilling operations, the joining material remains contained while maintaining the firm connection and alignment precision between the cutting head and holding shank.
Data Source
AI summary
A tool system for machining a workpiece is provided having a cylinder-shaped retaining shank that has a cutting head holder on an end surface facing the workpiece, a drive mount on an end surface facing the drive, a cutting head having at least one cutting edge, a cutting head hub corresponding to the cutting head holder on the retaining shank, a tool coupling with a tool interface, and a coupling hub corresponding to the drive mount. The coupling hub or the cutting head hub have elevated areas, with contact surfaces, distributed in circumferential and longitudinal directions of the coupling hub or the cutting head hub. The contact surfaces make contact on support surfaces on the drive mount or on the cutting head holder on the retaining shank. The drive mount or the cutting head holder is permanently connected to the coupling hub or the cutting head hub by a joining material in intermediate spaces between the elevations.