Modular Honing Tool Support Strips for Rapid Dressing
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Solution Overview
Problem
The existing honing tool regeneration process is complex and costly, requiring multiple identical tools to ensure quick tool exchange and minimal downtime, especially in form honing where honing stones have a short service life and minimal abrasive volume.
Innovation Solution
A method and device for individually adjusting honing tool support strips, allowing for the circulation of fewer honing tools by producing and stocking pre-made tools that can be easily swapped, along with a dressing device for honing stones that can dress multiple stones in one operation, reducing labor and capital costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If conventional regenerating process is used with multiple identical tools, then quick tool exchange is ensured, but the number of tools required and capital demand increase significantly
Solution Approach 1:
The honing tool is segmented into modular components: a reusable tool body and exchangeable support strips with honing stones. This segmentation allows the expensive tool body to be used repeatedly while only the cheaper support strips are exchanged, reducing the number of complete tools needed from multiple identical tools to just one tool body with interchangeable strips.
Solution Approach 2:
Instead of regenerating complete honing tools, the invention discards worn support strips and recovers/reuses the expensive tool body. The support strips with honing stones are replaced when worn, while the tool body remains in service, thereby reducing capital demand and the number of tools required.
2Adaptability or versatility
If short honing stones are used for form honing, then the honing process is enabled for non-cylindrical bores, but the service life is reduced and stones must be exchanged frequently
Solution Approach 1:
Multiple support strips with freshly dressed honing stones are prepared in advance and stocked. When the current support strip is worn, a pre-prepared replacement strip is immediately installed, eliminating downtime and ensuring continuous production without waiting for regeneration processes.
Solution Approach 2:
The support strips with honing stones are designed as disposable or limited-life components that are replaced rather than regenerated. This approach is economically justified because the tool body is expensive and reusable, while the support strips are cheaper and can be quickly replaced, effectively treating them as short-living objects.
3Manufacturing precision
If complex regenerating process is applied, then honing stones are properly prepared, but labor time and processing expenditure increase
Solution Approach 1:
The complex regeneration operations (cylindrical grinding, straightening, radius regrounding) are extracted from the tool body and applied only to the removable support strips. This allows the complex processes to be performed on small, isolated components rather than complete tools, simplifying the overall system and reducing the number of tools needing such treatment.
Solution Approach 2:
Instead of regenerating the original tool, new support strips are created as copies with freshly dressed honing stones. These copies can be prepared in advance and stocked, allowing immediate replacement without going through the complex regeneration process during production downtime.
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 significantly reduces the number of honing tools needed, minimizes processing time, and ensures precise abrasive surface positioning, resulting in cost savings and improved efficiency by allowing one honing tool to be in use while another is being furnished with new stones.
Implementation Method 1
The outer circumference of the mandrel is ground in a known manner to a curved surface having a radius of curvature corresponding to the radius of a bore to be honed
Implementation Method 2
The honing stones are pressed against the ground outer circumference of the mandrel and are dressed thereby with their working surfaces
Data Source
AI summary
A dressing device for dressing honing stones is provided with a base body and a mounting device for mounting the dressing device in a grinding machine. The base body has at least one honing stone receptacle that is a pocket. Honing stones are inserted and secured in the honing stone receptacles and the abrasive coating of the honing stones are ground by the grinding machine. A set of honing stones that is required for furnishing a honing tool can be dressed by one mounting action in the dressing device and can be inserted into the honing tool so as to be positioned exactly at the same radial position without requiring additional machining.