Tool Insert Seating Surfaces Embossing Play-Free Fit
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Solution Overview
Problem
Existing methods for producing connections between tool inserts and carriers often result in dimensional differences due to machining, leading to play and reduced torque transmission efficiency.
Innovation Solution
The method employs a sintered compact as an embossing die to form seating surfaces in the tool carrier, ensuring precise engagement and eliminating play by using the same tools for both the tool insert and carrier, with indexing features ensuring correct rotational alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If machining is used to produce seat surfaces in the tool carrier, then manufacturing flexibility is improved, but dimensional accuracy deteriorates leading to play between components
Solution Approach 1:
The sintered compact serves as a copy of the final tool insert, containing the seat surface geometry. By using this compact as an embossing die, the seat surfaces in the tool carrier are created as a copy of the insert's seat surfaces, ensuring identical dimensions and eliminating play without requiring separate machining operations.
Solution Approach 2:
The seat surfaces are formed in advance during the sintering process of the compact. The pressing tool creates the seat surface geometry on the compact before it becomes the final tool insert, and this pre-formed geometry is then used to emboss the tool carrier, eliminating the need for subsequent machining operations.
2Device complexity
If traditional machining methods are used for seat surfaces, then manufacturing process simplicity is improved, but connection precision deteriorates due to dimensional variations
Solution Approach 1:
The production of the tool insert and the formation of the seat surfaces in the tool carrier are merged into a single embossing operation. The sintered compact is used directly as the embossing die, combining the functions of tool insert manufacturing and carrier seat surface formation, thereby ensuring precise dimensional matching without separate machining steps.
3Adaptability or versatility
If separate production methods are used for tool insert and carrier seat surfaces, then manufacturing independence is improved, but fitting accuracy deteriorates resulting in play
Solution Approach 1:
The sintered compact acts as an intermediary between the tool insert design and the tool carrier production. It transfers the precise seat surface geometry from the insert to the carrier through the embossing process, ensuring that both components have matching dimensions while allowing independent manufacturing of different insert designs.
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 approach achieves a play-free, precise fitting with enhanced strength and accuracy, reducing material usage and manufacturing costs while ensuring accurate torque transmission.
Implementation Method 1
a sintered compact for the tool insert is used as an embossing die
Implementation Method 2
the seating surfaces in the tool carrier are produced by compression molding
Data Source
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AI summary
Method for producing a positive connection between a tool insert and a tool carrier of a rotatingly driven tool, wherein the tool carrier has seating surfaces (14, 30, 70) via which forces or torques are transmitted to the tool insert, wherein the tool insert is made of a harder material than the tool carrier and by sintering a powder compact (10). A sintered compact for the tool insert is used as a stamping die, with which the seating surfaces in tool carriers are produced by stamping or compression molding.