Modular Drill with Recycled Carbide Shank

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Solution Overview

Problem

Solid carbide drills are expensive and prone to high wear, despite their durability, making them less cost-effective for long-term use in machining applications.

Innovation Solution

A modular rotating tool design featuring a carbide cutting shank with an intermediate tool steel shank and a cutting insert, where the intermediate shank provides elasticity for secure clamping without additional fasteners, and the cutting shank is recycled from used tools to reduce material costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If solid carbide drills are used, then wear resistance and stiffness are improved, but manufacturing cost increases significantly

Engineering Contradiction:

Improvewear resistanceVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The drill is divided into multiple segments with different materials: a carbide cutting shank for wear resistance, a tool steel intermediate shank for elasticity and cost reduction, and a modular cutting insert. This segmentation allows each part to be optimized for its specific function while reducing overall manufacturing cost compared to solid carbide drills.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The drill combines different materials (carbide and tool steel) in a composite structure. The carbide cutting shank provides wear resistance where needed, while the tool steel intermediate shank provides elasticity and reduces cost. This composite approach optimizes the balance between performance and manufacturing cost.

Inventive Principle:

Principle #40Composite materials

2Strength

If solid carbide drills are used, then stiffness is improved, but manufacturing cost increases significantly

Engineering Contradiction:

ImprovestiffnessVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The drill implements local quality by using carbide only in the cutting shank where high stiffness and wear resistance are critical for cutting performance. The intermediate shank uses the less expensive tool steel, which provides sufficient stiffness for its structural role while reducing overall manufacturing cost.

Inventive Principle:

Principle #3Local quality

3Adaptability or versatility

If modular design with replaceable cutting insert is used, then adaptability is improved, but device complexity increases

Engineering Contradiction:

ImproveadaptabilityVSAvoiddevice complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The drill is segmented into a cutting insert, cutting shank, and intermediate shank, allowing the cutting insert to be replaced independently. This segmentation provides adaptability for different cutting applications while keeping the overall structure relatively simple through standardized coupling interfaces.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The intermediate shank acts as an intermediary component that couples the carbide cutting shank with the cutting insert. This mediator provides the elastic clamping function and simplifies the connection interface, reducing the overall device complexity while maintaining adaptability.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Ease of operation

If intermediate shank made of elastic material is used, then ease of operation is improved through secure clamping, but manufacturing precision requirements increase

Engineering Contradiction:

Improveease of operationVSAvoidmanufacturing precision

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The intermediate shank utilizes the elastic properties of tool steel, changing the mechanical parameter of stiffness to provide secure clamping of the cutting insert. This elastic material choice improves ease of operation through reliable clamping while the manufacturing precision requirements are managed through standard machining processes for the intermediate shank dimensions.

Inventive Principle:

Principle #35Parameter changes

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 design achieves a cost-effective rotating tool with improved wear resistance and extended service life by utilizing recycled carbide materials and maintaining modularity, while minimizing the use of expensive carbide.

Implementation Method 1

an intermediate shank (12) made of a material of greater elasticity in comparison to the material of the cutting insert (14), in particular a tool steel... The intermediate shank (12) is preferably made of an HSS steel... Sufficient elasticity for accommodating the cutting insert is required particularly in an embodiment of this type having the clamping webs

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS9724765B2Rotating tool, in particular drill, as well as a method for manufacturing a rotating tool of this type

Publication Date: 2017.08.08 KENNAMETAL INC

AI summary

The rotating tool, in particular a drill, includes a fluted cutting shank made of a resistant material, in particular carbide, extending in an axial direction along a rotational axis. Connecting to the cutting shank in the axial direction is an intermediate shank made of a material of greater elasticity in comparison the resistant material, in particular of tool steel. The intermediate shank includes an insertable cutting insert that may be exchanged. The cutting shank is preferably a cutting shank recycled from a used solid carbide drill.