Reamer Cutter Plate Layout for Controlled Bore Roughening
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Solution Overview
Problem
Conventional reamers produce surfaces that are too smooth for certain applications, such as bolt holes in connecting rods, where a higher surface roughness is required for better grip of plain bearing elements, and existing solutions with gravers have unsatisfactory service life and require significant adjustment efforts.
Innovation Solution
A reamer design featuring a base body with knife plates having a friction stage and a roughening stage, where the roughening stage is positioned at a defined distance from the friction stage, allowing for minimal adjustment effort and extended service life by providing a specific surface roughness through multiple friction stages and roughening edges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single burin is used to roughen the surface, then the surface roughness is improved, but the service life of the tool deteriorates
Solution Approach 1:
The single burin is segmented into multiple roughening edges (at least three) distributed on cutter plates. This segmentation distributes the mechanical load and wear across multiple edges, preventing any single edge from becoming excessively worn, thereby extending the overall service life of the reamer while maintaining effective surface roughness.
Solution Approach 2:
The invention enables selective replacement of individual cutter plates with roughening edges that have become worn, while retaining other cutter plates that are still serviceable. This allows the tool to continue operating with reduced functionality rather than requiring complete tool replacement, effectively extending the usable life of the reamer.
2Manufacturing precision
If the burin is located far from the fixed reaming edge, then the surface roughness can be adjusted, but the adjustment effort increases considerably
Solution Approach 1:
The invention transitions from a static, fixed-distance burin configuration to a dynamic system where multiple cutter plates with varying roughening edge positions can be selectively installed. This allows the effective roughening distance to be adjusted by simply changing which cutter plate is installed, rather than mechanically adjusting a single burin position, significantly reducing adjustment effort.
Solution Approach 2:
Multiple cutter plates are pre-configured with different roughening edge positions and projections during manufacturing. When adjustment is needed, the appropriate pre-configured cutter plate is simply selected and installed, eliminating the need for complex real-time adjustments and reducing operational complexity.
3Duration of action of stationary object
If multiple roughening stages are provided on multiple blade inserts, then the wear on individual roughening stages is reduced, but the device complexity increases
Solution Approach 1:
Each cutter plate serves multiple functions: it contains both reaming edges for precision boring and roughening edges for surface texturing. This multi-functionality allows the same component to perform multiple operations, reducing the need for separate tools or complex multi-component systems while still providing multiple roughening stages across different cutter plates.
Solution Approach 2:
The invention uses multiple identical or similar cutter plates, each with the same basic structure and geometry, rather than designing a complex single-component system. This modular copying approach simplifies manufacturing and maintenance while distributing wear across multiple identical units, reducing overall system complexity.
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 reamer effectively produces a surface with desired roughness for connecting rod applications, ensuring a long service life with reduced wear and minimal adjustment effort, while maintaining high productivity and surface quality.
Implementation Method 1
a roughening step with at least one roughening edge... arranged and configured to impart a specific roughness to a material surface
Data Source
Figure 1a~1b
Figure 2
Figure 3
AI summary
The invention relates to a reamer (3), having a main body (5) and at least one cutting tip (1) arranged on the main body (5), the cutting tip (1) having a reamer section (7), the cutting tip (1) having, at a distance (A) from the reamer section (7), a roughening section (9) having at least one roughening blade (11), the at least one roughening blade (11) protruding beyond the roughening section (7) by a particular projection (D).