Machine Reamer Cutting Ring Assembly Without Hard Soldering
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Solution Overview
Problem
Machine reamers with cutting edges from cermet, PKD, and CBN materials are expensive due to high production costs, making them uneconomical for piece or small series production, primarily due to costly blanks and laborious machining processes, including electro-erosive cooling channel creation and hard soldering, which can lead to tool destruction.
Innovation Solution
The machine reamer design features longitudinal grooves with a 90°-120° peak angle and radial clearance for adhesive joining of the cutting ring to the shank, allowing for cheaper production by pressing blanks and eliminating the need for hard soldering, enabling cost-effective assembly and inner channel creation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If hard soldering is used to join cutting edges to the reamer body, then strong bonding is achieved, but inner tensions occur and production costs increase
Solution Approach 1:
The patent replaces the thermal joining process (hard soldering) with a mechanical interference fit system. The conical centering pin with longitudinal groove engages with a corresponding conical opening in the cutting ring, creating a friction-based mechanical bond that eliminates the need for soldering entirely. This substitution removes the harmful thermal effects and associated costs while maintaining strong bonding.
Solution Approach 2:
The patent introduces an intermediary adhesive material filled into the longitudinal groove of the centering pin to enhance the mechanical bond between the cutting ring and reamer body. This adhesive intermediary works in conjunction with the mechanical interference fit to create a strong, tension-free connection that combines the advantages of both mechanical and chemical bonding without the drawbacks of hard soldering.
2Temperature
If electro-erosive method is used to create cooling channels, then cooling capability is achieved, but inner cracks occur and tool destruction risk increases
Solution Approach 1:
The patent replaces the electro-erosive machining process with a mechanical drilling or routing process to create cooling channels. The conical centering pin assembly provides a stable, vibration-free platform for channel creation that avoids the high-stress electro-erosive method. This substitution eliminates inner crack formation while maintaining effective cooling capability through properly positioned channels in the cutting ring.
3Strength
If monolitic cermet bars are used as blanks, then cutting edge material is achieved, but limited dimension assortment and high blank cost occur
Solution Approach 1:
The patent segments the reamer into distinct functional components: a steel or sintered carbide body for structural support and cooling channels, and a separate cutting ring made from cermet, PKD, or CBN material. This segmentation allows each component to be optimized independently and assembled through the conical interference fit, providing flexibility in material selection and reducing dependency on expensive monolitic cermet bars.
Solution Approach 2:
The patent creates a composite structure combining different materials with complementary properties: the steel or sintered carbide body provides toughness, thermal conductivity for cooling, and cost-effectiveness, while the cutting ring provides hard, wear-resistant cutting edges. This composite approach leverages the strengths of each material while mitigating their individual weaknesses, particularly the high cost and limited availability of monolitic cermet blanks.
4Manufacturing precision
If complex assembly with centering arbor and splines is used, then precise centering is achieved, but device complexity and production cost increase
Solution Approach 1:
The patent extracts and eliminates the complex centering arbor with splines and seats from the assembly. Instead, the conical centering pin with longitudinal groove is directly integrated into the reamer body, providing precise centering functionality as an inherent part of the tool structure rather than as a separate, complex assembly component. This simplification maintains centering precision while dramatically reducing device complexity.
Solution Approach 2:
The patent merges the centering function with the cutting ring mounting function into a single integrated conical centering pin assembly. The longitudinal groove in the centering pin serves dual purposes: providing precise radial centering alignment and serving as the adhesive bonding interface for securing the cutting ring. This merging of functions eliminates multiple separate components and simplifies the overall assembly process.
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 design reduces production costs by at least 50%, making machine reamers with cermet, PKD, and CBN cutting edges economically viable for piece production and simplifies assembly, while maintaining high machining precision and durability.
Implementation Method 1
the shape profile of the opening in the cutting ring is arranged on the shape profile of the centering pin with a radial clearance of 0,05 - 0,1 mm for fulfilling with an adhesive material and for achievement of a non-taking apart joint of the cutting ring with the supporting portion of the shank of the machine reamer after its hardening
Data Source
Figure 1~4
AI summary
Machine reamer (1) with cutting edges (18) from progressive cutting materials, consisting of a shank (16) with a clamping portion (3), by which the shank (16) is clamped in a not shown spindle of a machine tool and with a supporting portion (2), wherein in the center of the shank (16) of the machine reamer there is a through-channel (5) for cooling liquid, wherein the supporting portion (2) of the shank (16) is terminated by on its free end with a centering pin (13), on the centering ring (13) a cutting ring (4) with a central opening is arranged, wherein on the circumference of the centering pin (13) and also of the opening in the cutting ring (4) shape profiles are provided, with mutually corresponding shapes, and the shape profiles (11,12) of the centering pin (13) and of the opening in the cutting ring (4) are created as longitudinal grooves parallel with the axe of the machine reamer (1) with a peak angle of 90°-120° and with a depth of 0,3 - 0,5 mm and the shape profile (11) of the opening in the cutting ring (4) is arranged on the shape profile (12) of the centering pin (13) with a radial clearance of 0,05 - 0,1 mm for fulfilling with an adhesive material and for achievement of a non-taking apart joint of the cutting ring (4) with the supporting portion (2) of the shank (16) of the machine reamer (1) after its hardening.