Laser cladding cutting disc manufacturing process
By using diamond roller rolling and ultrasonic impact treatment, the problem of incomplete stress relief in laser cladding disc cutters using traditional heat treatment methods has been solved, improving the density and bonding strength of the cladding layer and enhancing the wear resistance and anti-peeling ability of the cutter.
Patent Information
- Application Number
- CN202511302781.4
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-09-12
- Publication Date
- 2025-11-21
AI Technical Summary
Traditional tempering can only release 30% to 40% of the residual stress on the surface, and has a weak effect on stress relief deep in the cladding layer. Although annealing can reduce stress levels through slow cooling, it will cause the hardness of the cladding layer to decrease by 15% to 20%, sacrificing the wear resistance of the tool. More importantly, the residual tensile stress that is not eliminated is superimposed on the cutting force, which can easily form microcracks on the cutting edge.
A combination of diamond roller rolling and ultrasonic impact treatment is used. Rolling eliminates surface porosity and micro-defects, generating residual stress. Ultrasonic impact effectively eliminates residual stress, improves the bonding interface between the cladding layer and the substrate, and enhances the toughness and anti-peeling ability of the cladding layer.
It effectively eliminates residual stress, increases the density and bonding strength of the cladding layer, avoids stress concentration, enhances the wear resistance and anti-stripping ability of the tool, and ensures the stability of the cutting edge.
Smart Images
Figure CN120989609A_ABST
Abstract
Description
Technical Field
[0001] This invention belongs to the field of disc cutter manufacturing technology, specifically relating to a laser cladding disc cutter manufacturing process. Background Technology
[0002] Laser-clad disc cutters are manufactured by applying a high-hardness alloy coating (such as WC-Co or nickel-based alloys) to the surface of a low-carbon steel or alloy steel substrate using laser cladding technology. This creates a cutting edge structure that combines high wear resistance and impact resistance. This technology overcomes the limitations of traditional integral forging processes, achieving material optimization by "using the best steel on the cutting edge," significantly reducing costs and improving performance.
[0003] Laser cladding saves 70% of material compared to solid carbide cutting tools, increases powder utilization to 95%, reduces energy consumption by 60% compared to traditional heat treatment, and produces no wastewater.
[0004] Specifically, in the traditional manufacturing process of laser cladding disc cutters, the post-heat treatment stage often relies on heat processing methods such as tempering and annealing to eliminate the internal stress of the cladding layer. However, this type of process has significant technical bottlenecks. During laser cladding, a high-energy laser beam causes the cladding material to melt instantly and solidify rapidly. Due to the difference in thermal expansion coefficients, a severe temperature gradient is formed at the interface between the cladding layer and the substrate. The resulting thermal stress and the structural stress induced by the martensitic phase transformation are superimposed to form a complex three-dimensional stress field. However, traditional tempering can only release 30% to 40% of the residual stress on the surface, and has a weak effect on stress relief deep in the cladding layer. Although annealing can reduce stress levels through slow cooling, it will cause the hardness of the cladding layer to decrease by 15% to 20%, sacrificing the wear resistance of the tool. More importantly, when the disc cutter is used for high-speed cutting, the unrelieved residual tensile stress will be superimposed with the alternating stress generated by the cutting force, which is very easy to form microcracks on the cutting edge. Summary of the Invention
[0005] The purpose of this invention is to provide a manufacturing process for laser cladding disc cutters, which aims to solve the problems of traditional tempering, which can only release 30% to 40% of the residual stress on the surface and has a weak effect on stress relief deep in the cladding layer; although annealing can reduce stress levels through slow cooling, it will cause the hardness of the cladding layer to decrease by 15% to 20%, sacrificing the wear resistance of the tool; more importantly, when the disc cutter is used for high-speed cutting, the unrelieved residual tensile stress will be superimposed with the alternating stress generated by the cutting force, which is very easy to form microcracks on the cutting edge.
[0006] To achieve the above objectives, the present invention provides the following technical solution: a laser cladding disc cutter manufacturing process, comprising the following steps: Step 1: Prepare the blank for the disc cutter: Select steel plate as the blank for making the disc cutter; Step 2, machining and grinding: The cutting edge of the selected steel plate blank is machined and ground. Step 3: Polishing: Use sandpaper to polish the blade edge; Step 4: Cleaning: Clean the fused areas of the blade with acetone to remove surface dust and oil impurities, then wipe with anhydrous ethanol, and finally place in a ventilated and dry place for later use. Step 5: Alloy powder proportioning and mixing: Prepare the powder raw materials for laser cladding coating according to the proportions and mix them evenly; Step 6: Drying: Dry the uniformly mixed alloy powder at high temperature for two hours; Step 7, Powder Loading: Load the dried powder into the powder feeder inside the laser cladding device to complete the powder loading process; Step 8, cladding: Install and position the blade on the laser cladding equipment, start the laser cladding equipment, and focus the laser beam on the cutting edge of the blade, where the alloy powder melts and clads onto the blade to form a cladding layer; Step 9, Post-heat treatment: After laser cladding, the tool body is subjected to post-heat treatment by annealing; Step 10, Surface Rolling: Apply pressure to the surface of the cladding layer using a hard roller on the post-heat treated disc cutter and roll it. Step 11, Ultrasonic Impact Treatment: After rolling, the disc cutter applies periodic pressure to the surface of the cladding layer through a high-frequency vibrating impact head; Step 12, Subsequent processing: Weld the stress-relieved disc cutter body to the cutter shank and perform grinding and polishing treatment; Step 13, Cleaning and Oil Immersion: Clean the disc cutter body to remove residual oil, debris and impurities from the processing, and then immerse it in oil. Step 14: Quality Inspection: Conduct quality inspection on the finished disc cutter, including appearance inspection, dimensional measurement, hardness testing, blade sharpness testing, and wear resistance testing, to ensure that the cutter meets relevant standards and usage requirements; Step 15: Packaging and Warehousing: Package the finished disc cutters that meet the specifications and store them in the warehouse.
[0007] As a laser cladding disc cutter manufacturing process of the present invention, preferably, the surface rolling treatment in the tenth step uses a diamond roller material, and the rolling pressure of the diamond roller is in the range of 200-600 MPa, and the rolling amount on one side is controlled between 0.01 and 0.05 mm.
[0008] As a laser cladding disc cutter manufacturing process of the present invention, preferably, the high frequency range of the ultrasonic impact treatment in the eleventh step is 15-30KHz, wherein the ultrasonic impact system consists of an ultrasonic generator, a transducer, an amplitude transformer and an impact head.
[0009] As a laser cladding disc cutter manufacturing process of the present invention, preferably, the amplitude transformer amplifies the amplitude of the mechanical vibration, wherein the amplification range is 0.05 to 0.3 mm, and the material selected for the impact head is cemented carbide, and the shape of the impact head is adapted to the cutting edge of the disc cutter.
[0010] As a preferred method for manufacturing a laser cladding disc cutter according to the present invention, the impact head is at a ratio of 10... 4 -10 5 The cladding layer surface is repeatedly impacted at a frequency of times per second.
[0011] Compared with the prior art, the beneficial effects of the present invention are: This invention involves post-heat treatment of the cladding disc cutting edge, followed by rolling treatment on the bottom of a diamond roller. This densifies the material on the surface of the cladding layer, eliminating surface porosity and micro-defects, increasing density, and generating residual stress in the cladding layer to prevent stress concentration. The rolled disc cutting body is then subjected to ultrasonic impact treatment. During this process, an ultrasonic generator produces high-frequency electrical vibrations, which are repeatedly impacted by an impact head to efficiently eliminate residual stress, improve the bonding interface between the cladding layer and the substrate, and enhance the toughness and anti-peeling ability of the cladding layer. Attached Figure Description
[0012] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used in conjunction with embodiments of the invention to explain the invention and do not constitute a limitation thereof. In the drawings: Figure 1 This is a schematic diagram of the process flow provided for an embodiment of this application.
[0013] Figure 2 A schematic diagram illustrating the subsequent processing principle provided in the embodiments of this application.
[0014] Figure 3 A schematic diagram of stress changes provided for an embodiment of this application. Detailed Implementation
[0015] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.
[0016] Please see Figure 1-2 The present invention provides the following technical solution: a laser cladding disc tool manufacturing process, comprising the following steps: Step 1: Prepare the blank for the disc cutter: Select steel plate as the blank for making the disc cutter; Step 2, machining and grinding: The cutting edge of the selected steel plate blank is machined and ground. Step 3: Polishing: Use sandpaper to polish the blade edge; Step 4: Cleaning: Clean the fused areas of the blade with acetone to remove surface dust and oil impurities, then wipe with anhydrous ethanol, and finally place in a ventilated and dry place for later use. Step 5: Alloy powder proportioning and mixing: Prepare the powder raw materials for laser cladding coating according to the proportions and mix them evenly; Step 6: Drying: Dry the uniformly mixed alloy powder at high temperature for two hours; Step 7, Powder Loading: Load the dried powder into the powder feeder inside the laser cladding device to complete the powder loading process; Step 8, cladding: Install and position the blade on the laser cladding equipment, start the laser cladding equipment, and focus the laser beam on the cutting edge of the blade, where the alloy powder melts and clads onto the blade to form a cladding layer; Step 9, Post-heat treatment: After laser cladding, the tool body is subjected to post-heat treatment by annealing; Step 10, Surface Rolling: Apply pressure to the surface of the cladding layer using a hard roller on the post-heat treated disc cutter and roll it. Step 11, Ultrasonic Impact Treatment: After rolling, the disc cutter applies periodic pressure to the surface of the cladding layer through a high-frequency vibrating impact head; Step 12, Post-processing: Weld the stress-relieved disc cutter body to the handle and perform grinding and polishing; if necessary, sharpen the cutting edge. Step 13, Cleaning and Oil Immersion: Clean the disc cutter body to remove residual oil, debris and impurities from the processing, and then immerse it in oil. Step 14: Quality Inspection: Conduct quality inspection on the finished disc cutter, including appearance inspection, dimensional measurement, hardness testing, blade sharpness testing, and wear resistance testing, to ensure that the cutter meets relevant standards and usage requirements; Step 15: Packaging and Warehousing: Package the finished disc cutters that meet the specifications and store them in the warehouse.
[0017] Preferably, in the tenth step, the surface rolling treatment uses diamond rollers, and the rolling pressure of the diamond rollers is in the range of 200-600 MPa. In addition, the rolling amount on one side is controlled between 0.01 and 0.05 mm.
[0018] Preferably, the high frequency range in the ultrasonic impact treatment process of the eleven steps is 15-30KHz, and the ultrasonic impact system consists of an ultrasonic generator, a transducer, an amplitude transformer and an impact head.
[0019] Preferably, the amplitude transformer amplifies the amplitude of the mechanical vibration, wherein the amplification range is 0.05 to 0.3 mm, and the material selected for the impact head is cemented carbide, while the shape of the impact head is adapted to the cutting edge of the disc blade.
[0020] Preferably: the impact head is at 10 4 -10 5 The surface of the cladding layer is repeatedly impacted at a frequency of times per second.
[0021] In practical use, the ultrasonic generator converts the power frequency electrical signal into high-frequency electrical vibration, the transducer converts the electrical vibration into mechanical vibration, the amplitude transformer amplifies the amplitude of the mechanical vibration, and the impact head transfers the high-frequency vibration energy to the surface of the cladding layer at a frequency of 10. 4 -10 5 The surface is repeatedly impacted at a frequency of times per second. The high-frequency impact causes intense plastic flow in the surface of the cladding layer. The residual tensile stress inside the material is "relaxed" under the action of impact energy, and part of it is converted into plastic deformation work and eventually released. After the surface material undergoes plastic flow, the undeformed areas inside will "constrain" the surface, causing residual compressive stress to form on the surface. The intense plastic deformation caused by the impact generates a large number of dislocations on the surface of the cladding layer. The accumulation and interaction of dislocations trigger dynamic recrystallization, refining the coarse columnar crystals or dendrites formed by laser cladding into ultrafine crystals. The tiny pores and microcracks in the cladding layer are "compacted" or closed under impact pressure, reducing stress concentration points and enhancing the interfacial bonding strength between the cladding layer and the substrate.
[0022] like Figure 3 As shown, the stress distribution of the cladding layer of the disc cutter after laser cladding has typical characteristics, while ultrasonic impact treatment will significantly change its stress state. The specific changes can be intuitively reflected by the "stress-depth curve": the horizontal axis is the depth from the surface, the vertical axis is the stress value, tensile stress is positive, and compressive stress is negative.
[0023] Example 1: Stress distribution before treatment (after laser cladding): Surface layer (0-50μm): Due to rapid solidification and shrinkage constrained by the matrix, there is usually a residual tensile stress of 100-300MPa, which is prone to becoming a crack initiation. Subsurface layer (50-200μm): Tensile stress gradually decreases, and stress fluctuations may occur due to segregation of cladding layer composition or differences in grain orientation; The interface between the cladding layer and the substrate (200-500μm) is a high-risk area for cladding layer peeling due to the difference in thermal expansion coefficients. Inside the matrix (>500μm): the stress gradually becomes gentler, approaching the original stress state of the matrix.
[0024] Example 2: Stress distribution after treatment (after ultrasonic impact): Surface layer (0-50μm): Tensile stress is completely converted into residual compressive stress, ranging from -200 to -500MPa, which is the "beneficial stress" introduced by impact plastic deformation; Subsurface layer (50-200μm): The compressive stress gradually decreases, transitioning from -500MPa to -100MPa, and the stress gradient is gentler (avoiding local embrittlement caused by sudden stress changes). Cladding layer-substrate interface (200-500μm): The original peak tensile stress is significantly reduced, from 300-500MPa to 50-100MPa tensile stress, or even turns into mild compressive stress, and the interfacial bonding stability is significantly improved; Inside the matrix (>500μm): the stress is basically unaffected, as the impact energy mainly acts on the cladding layer and the near-interface region.
[0025] The advantages of this invention over existing technologies are as follows: First, after post-heat treatment of the cladding disc cutting edge, the cutting body is placed on the bottom of a diamond roller for rolling treatment. This densifies the material on the surface of the cladding layer, eliminates surface porosity and micro-defects, increases density, and generates residual stress in the cladding layer, preventing stress concentration. Then, the rolled disc cutting body undergoes ultrasonic impact treatment. During this process, an ultrasonic generator produces high-frequency electrical vibrations, which are repeatedly impacted by an impact head, effectively eliminating residual stress, improving the bonding interface between the cladding layer and the substrate, and enhancing the toughness and anti-peeling ability of the cladding layer. Finally, it should be noted that the above descriptions are merely preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.
Claims
1. A laser cladding disc tool manufacturing process, characterized in that, Includes the following steps: Step 1: Prepare the blank for the disc cutter: Select steel plate as the blank for making the disc cutter; Step 2, machining and grinding: The cutting edge of the selected steel plate blank is machined and ground. Step 3: Polishing: Use sandpaper to polish the blade edge; Step 4: Cleaning: Clean the fused areas of the blade with acetone to remove surface dust and oil impurities, then wipe with anhydrous ethanol, and finally place in a ventilated and dry place for later use. Step 5: Alloy powder proportioning and mixing: Prepare the powder raw materials for laser cladding coating according to the proportions and mix them evenly; Step 6: Drying: Dry the uniformly mixed alloy powder at high temperature for two hours; Step 7, Powder Loading: Load the dried powder into the powder feeder inside the laser cladding device to complete the powder loading process; Step 8, cladding: Install and position the blade on the laser cladding equipment, start the laser cladding equipment, and focus the laser beam on the cutting edge of the blade, where the alloy powder melts and clads onto the blade to form a cladding layer; Step 9, Post-heat treatment: After laser cladding, the tool body is subjected to post-heat treatment by annealing; Step 10, Surface Rolling: Apply pressure to the surface of the cladding layer using a hard roller on the post-heat treated disc cutter and roll it. Step 11, Ultrasonic Impact Treatment: After rolling, the disc cutter applies periodic pressure to the surface of the cladding layer through a high-frequency vibrating impact head; Step 12, Subsequent processing: Weld the stress-relieved disc cutter body to the cutter shank and perform grinding and polishing treatment; Step 13, Cleaning and Oil Immersion: Clean the disc cutter body to remove residual oil, debris and impurities from the processing, and then immerse it in oil. Step 14: Quality Inspection: Conduct quality inspection on the finished disc cutter, including appearance inspection, dimensional measurement, hardness testing, blade sharpness testing, and wear resistance testing, to ensure that the cutter meets relevant standards and usage requirements; Step 15: Packaging and Warehousing: Package the finished disc cutters that meet the specifications and store them in the warehouse.
2. The laser cladding disc cutter manufacturing process according to claim 1, characterized in that: In the tenth step, the surface rolling treatment uses diamond rollers, and the rolling pressure of the diamond rollers is in the range of 200-600 MPa. In addition, the rolling amount on one side is controlled between 0.01 and 0.05 mm.
3. The laser cladding disc cutter manufacturing process according to claim 1, characterized in that: The high-frequency range of the ultrasonic impact treatment in the eleventh step is 15-30KHz, and the ultrasonic impact system consists of an ultrasonic generator, a transducer, an amplitude transformer, and an impact head.
4. The laser cladding disc cutter manufacturing process according to claim 1, characterized in that: The amplitude transformer amplifies the amplitude of the mechanical vibration, with an amplification range of 0.05 to 0.3 mm. In addition, the material selected for the impact head is cemented carbide, and the shape of the impact head is adapted to the cutting edge of the disc blade.
5. The laser cladding disc cutter manufacturing process according to claim 1, characterized in that: The impact head is at 10 4 -10 5 The surface of the cladding layer is repeatedly impacted at a frequency of times per second.