Overlay Insert Reamer for One-Pass Rough and Finish Machining
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Solution Overview
Problem
The existing machining head replacement type rotary tools have limited usage applications due to their fixed shape, preventing combined machining operations such as simultaneous rough and finish machining.
Innovation Solution
A reamer with a cylindrical body and a disc-shaped insert portion that can be configured by coaxially overlaying multiple inserts, featuring convex and concave portions for secure fixation and adjustable blade length, allowing for various machining types and improved tool rigidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed shape holder is used in machining head replacement type rotary tools, then the structure is simple and easy to manufacture, but usage applications are limited and combined machining cannot be performed
Solution Approach 1:
The reamer is divided into a body portion and a separate insert portion that can be detached and replaced. The insert portion includes multiple disc-shaped inserts that can be configured independently, allowing different machining operations to be performed by changing the insert configuration rather than redesigning the entire tool.
Solution Approach 2:
The holder body is designed with a universal attachment mechanism that can accommodate various types of inserts for different machining operations. By changing the insert configuration on the same holder, the tool can perform multiple functions including rough machining, finish machining, and combined machining operations.
2Adaptability or versatility
If only one machining head can be attached to the holder, then the structure is simple, but combined machining such as simultaneous rough and finish machining cannot be performed
Solution Approach 1:
The cutting portion is segmented into multiple independent disc-shaped inserts that can be arranged in different configurations. Each insert can be optimized for specific machining functions, and multiple inserts can work simultaneously on the same workpiece to perform combined machining operations.
Solution Approach 2:
Multiple disc-shaped inserts are arranged coaxially one after another in the axial direction, with each insert nested within the radial space of the holder. This nested arrangement allows multiple cutting elements to be positioned at different axial locations while maintaining a compact overall structure.
3Adaptability or versatility
If multiple disc-shaped inserts are coaxially overlaid to enable combined machining, then adaptability and combined machining capability are improved, but the axial length of the insert portion increases reducing tool rigidity
Solution Approach 1:
Multiple disc-shaped inserts are arranged coaxially within the radial space of the holder, with each insert positioned at different axial locations. This nested configuration allows multiple cutting elements to be integrated into a compact axial space, minimizing the protrusion length while maintaining the ability to perform combined machining operations.
Solution Approach 2:
Instead of arranging multiple inserts in a linear sequence along the axial direction, the inserts are arranged in a three-dimensional coaxial configuration within the radial space of the holder. This spatial arrangement in another dimension (radial vs. axial) allows multiple inserts to be packed into a compact volume without significantly increasing the axial protrusion length.
4Adaptability or versatility
If the insert portion protrudes long in the axial direction to accommodate multiple inserts, then combined machining is enabled, but run-out occurs during rotation reducing machining precision
Solution Approach 1:
Multiple disc-shaped inserts are arranged coaxially within the radial space of the holder, minimizing the axial protrusion length. This nested configuration reduces the leverage effect during rotation, thereby minimizing run-out and improving machining precision while still allowing flexible insert configurations for combined machining.
Data Source
Figure 1
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Figure 3
AI summary
An insert portion (3) of a reamer (1) is fixed, using screws (8), to a leading end portion of a body (2A). The insert portion (3) is configured by overlaying an insert (4) for finish machining and an insert (5) for rough machining, and forms a right hand cut right hand helix. On respective mating faces of the inserts (4, 5), convex portions and concave portions of the mating face of the insert (4) overlap with concave portions and convex portions of the mating face of the insert (5). The reamer (1) can enlarge a hole formed in a workpiece or change a shape of the hole. The inserts (4, 5) simultaneously cut an inner peripheral face of the hole, and can thus perform rough machining and finish machining in one pass. By overlapping the convex portions and the concave portions of each of the mating faces of the inserts (4, 5), they partially overlap in their respective thickness directions. A protrusion length of the insert portion (3) can thus be shortened.