Selective Outer-Diameter Honing Tool Using Triangular Abrasive Belt
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Solution Overview
Problem
Existing honing technologies for outer-diameter of pipes and precision cylindrical tubing are limited by the use of expensive and fragile abrasive stones, which are not suitable for selective material removal and can only handle small amounts of material, while also being inefficient in reducing ovality and achieving precise finishes.
Innovation Solution
A low-cost tool using sanding belts instead of honing stones, where the belt width defines the honed area length, with a triangular shaped belt configuration to achieve high pressure and controlled material removal, and multiple assemblies to ensure concentricity and selective honing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If abrasive stones are used for outer-diameter honing, then a fine surface finish can be achieved, but the tool becomes expensive and fragile
Solution Approach 1:
The patent replaces expensive, fragile abrasive stones with inexpensive abrasive belts that can be easily replaced. The belts are mounted on a flexible backing material, allowing them to be discarded and replaced without special tooling, thus resolving the contradiction between achieving fine surface finish and maintaining tool durability.
Solution Approach 2:
The patent changes the fundamental parameter of the abrasive medium from rigid stones to flexible belts mounted on a compliant backing. This parameter change allows the abrasive material to conform to the workpiece surface while being replaceable, thereby achieving fine surface finish without the fragility and cost issues of traditional stones.
2Manufacturing precision
If abrasive stones are used for outer-diameter honing, then a fine surface finish can be achieved, but the tool cost increases
Solution Approach 1:
The patent substitutes costly abrasive stones with inexpensive abrasive belts that can be mass-produced and easily replaced. The belts are mounted on simple flexible backings, eliminating the need for expensive stone-setting machinery and reducing overall tool cost while maintaining surface finish quality.
Solution Approach 2:
The patent uses flexible backings that can be manufactured as simple copies or replicas of the desired shape, eliminating the need for expensive, custom-machined stone holders. This copying approach allows for standardized, low-cost tooling that achieves the same functional result.
3Manufacturing precision
If traditional honing stones are used, then small amounts of material can be removed, but large amounts of material removal is not feasible
Solution Approach 1:
The patent changes the abrasive medium from rigid stones to flexible belts, which can be applied with varying pressure and coverage area. This parameter change enables both light finishing passes and heavy material removal passes, resolving the contradiction between controlled material removal and high productivity.
Solution Approach 2:
The patent introduces dynamic flexibility through the belt system, allowing the operator to adjust pressure, belt speed, and contact area in real-time. This dynamic capability enables the same tool to perform both light honing and heavy material removal, unlike rigid stone systems.
4Productivity
If sanding belts are used for material removal, then both small and large amounts of material can be removed, but selective honing of specific areas becomes difficult
Solution Approach 1:
The patent divides the abrasive belt into discrete segments or zones, with different grit sizes or abrasive characteristics in different sections. This segmentation allows selective application of different abrasive actions to different areas of the workpiece, resolving the contradiction between material removal flexibility and area selectivity.
Solution Approach 2:
The patent applies different abrasive properties to different parts of the belt, creating local quality variations. This allows the operator to select specific portions of the belt for specific honing tasks, enabling both heavy material removal and precise selective honing with the same tool.
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 efficient removal of both small and large amounts of material with precise control over the material removal rate, reducing labor and tool wear, and effectively addressing ovality issues in pipes and tubing.
Implementation Method 1
Honing is a process to finish an object, such as a hole, to a final size, after an imprecise operation such as drilling, and to produce a fine surface finish. Honing is usually on the inner-diameter, but can also be done on the outer-diameter of an object.
Data Source
AI summary
A tool is disclosed for selective honing of the outer diameter of a cylinder using an abrasive belt in semi-circular contact upon the outer-diameter of a cylindrical work-piece to perform a similar function to honing the inner-diameter of a hollow cylinder. The belt is retained within the tool body by U-shaped restraint arms, and a slot in the tool body. A clamp block retains the ends of the belt which exit the slot. Springs on the arms, and contact of the block on the outside of the tool body, force the belt into a triangular shape inside the body. A cylindrical work-piece inserted within the triangular shaped belt causes the belt to deform into three semi-circular areas of contact between the belt and work-piece. When the work-piece is rotated, the belt abrades material from the work-piece.