Modular Honing Tool Components for Low-Vibration Diameter Ranges
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing honing tools require a complex assembly process and are prone to vibrations and noise, especially when machining large diameters, leading to suboptimal surface quality and increased preparation time.
Innovation Solution
A modular tool system with a tool body and support bar units, featuring adjustable guide pins and bolt guide elements, allows for quick assembly and stable operation across a wide diameter range without vibrations, using interchangeable components for different diameter ranges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If modular tool systems with multiple support bar units and guide pins are used to cover wide diameter ranges, then adaptability is improved, but device complexity increases and assembly time increases
Solution Approach 1:
The tool body is designed with multiple transverse bores arranged in bore groups around the circumference, allowing the same tool body to accommodate support bar units with different guide pin lengths. This universal design enables one tool body to cover multiple effective diameter ranges by simply changing the support bar units, rather than requiring different tool bodies for different diameter ranges.
Solution Approach 2:
The honing tool is divided into modular components: a reusable tool body and interchangeable support bar units. Each support bar unit contains guide pins of specific lengths that can be independently selected and replaced. This segmentation allows users to configure the tool for different diameter ranges by swapping only the support bar units, reducing the number of different tool bodies needed.
2Adaptability or versatility
If multiple sets of support bar units with different guide pin lengths are provided, then adaptability is improved, but assembly time increases
Solution Approach 1:
Different sets of support bar units with varying guide pin lengths are pre-configured to match specific bore group patterns. Users can quickly select the appropriate pre-configured set for their required diameter range, eliminating the need for on-site configuration or calculation of guide pin lengths. This preliminary preparation of standardized sets significantly reduces assembly preparation time.
3Adaptability or versatility
If longer guide pins are used to increase effective diameter range, then adaptability is improved, but vibration and noise increase
Solution Approach 1:
Instead of uniformly increasing guide pin lengths throughout the tool, the invention provides different sets of support bar units with locally optimized guide pin lengths for specific diameter ranges. Each set is tailored to provide sufficient length for the target diameter while minimizing excessive length that would cause vibration. This local optimization ensures adaptability across diameter ranges while controlling vibration and noise.
4Adaptability or versatility
If complex modular systems with multiple bore groups and support bar units are used, then adaptability is improved, but ease of operation deteriorates
Solution Approach 1:
Support bar units are pre-configured in standardized sets with guide pins of specific lengths matched to specific bore groups. This preliminary organization allows users to simply select the appropriate pre-configured set for their diameter requirement and install it, rather than having to calculate, select, and configure individual components. This dramatically simplifies operation for inexperienced users while maintaining full adaptability.
Data Source
Figure 1~3
Figure 4~5
Figure 6~9
AI summary
A tool system with tool components for configuring honing tools with different effective diameter ranges comprises at least one tool body (100-3) defining a tool axis (112) and having an axial bore (114) arranged coaxially to the tool axis (112) for receiving an infeed element, as well as a plurality of transverse bores (130) aligned transversely to the tool axis and open to the axial bore, each for receiving a guide pin (160), wherein the transverse bores (130) form a plurality of bore groups distributed over the circumference of the tool body, each having at least two transverse bores (130) arranged at an axial distance from one another; a plurality of sets of support bar units with guide pins (160) of different lengths from set to set for insertion into transverse bores of a bore group;and at least one set of bolt guide elements (410) which are designed to be mounted on the tool body, wherein a set of bolt guide elements has, for each of the transverse bores provided for receiving a guide bolt, a bolt guide element (410) with a guide bore formed therein which, when the bolt guide element is mounted on the tool body, runs coaxially with the transverse bore (130);