Multi-Zone Carbide Honing Shank for Precision Bore Finishing
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Solution Overview
Problem
Traditional honing tools require multiple passes and multiple diamond plated tools to achieve precision surface finishes, are time-consuming, and lack efficient alignment mechanisms, leading to inefficiencies and potential tool damage.
Innovation Solution
A honing apparatus with a shank featuring three zones of increasing diameters, each with progressively finer grit diamonds, and a centering section for precise alignment, allowing for single-tool precision surface finishing with adjustable oscillation cycles and made from durable carbide material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional diamond plated tools are used with multiple passes and multiple tools, then the desired surface finish can be achieved, but the process becomes time-consuming and requires frequent tool changes
Solution Approach 1:
The patent combines multiple honing zones with different grit sizes (coarse, medium, fine) onto a single tool body, allowing all zones to operate simultaneously during one pass. This eliminates the need for multiple tool changes and multiple passes, achieving the desired surface finish in a single operation while maintaining precision.
Solution Approach 2:
The single honing tool is designed to perform multiple functions by incorporating zones with different grit sizes that can handle different stages of material removal and surface finishing. The tool universally addresses roughing, semi-finishing, and final finishing operations in one tool, eliminating the need for specialized tools for each stage.
2Ease of manufacture
If traditional steel shank tools are used, then the tool can be manufactured, but the shank may twist and bend over time leading to misalignment
Solution Approach 1:
The patent replaces the traditional steel shank with a carbide shank, utilizing composite material properties. Carbide provides superior hardness, stiffness, and resistance to twisting and bending compared to steel, ensuring the tool maintains its straightness and alignment stability over time while still being manufacturable through standard carbide fabrication processes.
3Device complexity
If traditional tools without centering sections are used, then the tool structure is simpler, but manual realignment is required which is time-consuming and impractical
Solution Approach 1:
The patent incorporates a centering section at the leading end of the tool that automatically centers the tool within the workpiece bore during operation. This self-centering mechanism eliminates the need for manual realignment by the operator, allowing the tool to automatically adjust and maintain proper alignment throughout the honing process, saving time and improving practicality.
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
Enables high-precision surface finishing with reduced tool changes and time, maintaining tool straightness, and achieving precise bore sizing with a single tool, capable of thousands of operations before reconditioning.
Implementation Method 1
The precision surface is achieved by scrubbing an abrasive grinding wheel or abrasive grinding stone against the workpiece along a controlled path
Data Source
AI summary
A honing apparatus for producing a precision surface on a workpiece is disclosed. The honing apparatus includes a shank having a first zone positioned at substantially proximity to a distal end of the shank and a second zone positioned at substantially centre of said shank. The first zone has a rough grit diamond than the second zone. The honing apparatus includes a centering section positioned at the distal end of the shank. The shank connects to a honing machine via an adapter. The shank axially advances towards an area on a workpiece to be precision finished, while rotating and reciprocating relative to the workpiece to be precision surfaced. The centering section centers and aligns the shank at the workpiece such that the workpiece comes in contact with the first zone followed by the second zone. The first zone and the second zone remove a stock of material from the workpiece for precision surface on the workpiece.