Repair process for inlaid cutter

Abstract

The invention provides an embedded cutter repairing process, and belongs to the technical field of cutter repairing. The inlaid cutter repairing process comprises the following steps that S1, a damaged cutter head is removed, specifically, the damaged or seriously-abraded cutter head portion on an inlaid cutter is accurately positioned, and the laser cutting and high-frequency induction heating combined technology is adopted so that the influence of a heat affected zone on a cutter body structure can be reduced; according to the method, various advanced technologies such as laser cutting, high-frequency induction heating and vacuum brazing are combined, the abrasion resistance, hardness and impact resistance of the repaired tool are greatly improved, it is ensured that the welding position is free of cracks and air holes through the high-precision welding technology between the base metal of the tool and the new tool bit, and the tool quality is improved. The surface of the repaired tool is effectively strengthened through reasonable temperature control and cooling processes, the overall hardness and durability of the tool are greatly improved, the service life of the tool is prolonged, and the machining precision of the tool can be effectively kept.

Description

Technical Field

[0001] This invention relates to the field of tool repair technology, and more specifically, to an inlay tool repair process. Background Technology

[0002] Insert-type cutting tools are widely used in metal cutting processes such as turning, milling, planing, and broaching. Their cutting tips are usually made of cemented carbide, coated materials, or high-speed steel, while the cutting body is mostly made of structural steel or alloy steel. Under long-term high-load use, the cutting tips are prone to wear, chipping, cracks, and other damage, which can lead to the scrapping of the entire tool and increase production costs.

[0003] In existing technologies, the tool is usually replaced as a whole or the tool head is ground and reused. However, both of these methods have obvious drawbacks: replacement is costly and time-consuming; continued use will reduce machining accuracy and may even lead to workpiece scrap. Summary of the Invention

[0004] To overcome the above deficiencies, the present invention provides an inlay tool repair process that overcomes or at least partially solves the above technical problems.

[0005] This invention is implemented as follows: This invention provides an inlay-type tool repair process, comprising the following steps: S1: Remove damaged cutting head: Precisely locate the damaged or severely worn cutting head on the inlaid cutting tool, and use laser cutting combined with high frequency induction heating technology to reduce the impact of the heat-affected zone on the structure of the cutting tool body; S2: Cleaning the welding surface: Using a multi-step cleaning method that combines mechanical grinding, ultrasonic cleaning and high-pressure water jetting, oil, oxides and residues on the welding surface of the blade are thoroughly removed to avoid any welding defects; S3: Pre-processing assembly groove: The tool body inlay part is finely machined at the micron level, and an inlay groove with a tapered or self-locking structure is formed by CNC machine tool processing; S4: Select and assemble new cutting tips: Select cutting tips with high wear resistance and high hardness, such as cemented carbide, coated cemented carbide, or superhard materials, and coat the contact surface of the cutting tips with high-temperature adhesive or customized flux. S5: Welding and fixing: Vacuum brazing or argon-protected welding technology is used to weld the cutter head and cutter body with silver-based brazing or high-temperature cobalt-based solder. The temperature is controlled between 750℃ and 950℃ to ensure that the gas does not enter the welding area during the welding process, thus preventing oxidation and the formation of pores. S6: Heat treatment and cooling: After welding, the entire tool is subjected to heat treatment to eliminate residual welding stress and increase tool hardness. S7: Precision Dressing and Inspection: High-precision grinding and fine-tuning of the welded cutting tools to ensure that the geometry and cutting edge accuracy of the tool head meet the design requirements.

[0006] In a preferred embodiment, step S1 combines laser cutting with high-frequency induction heating to reduce the heat-affected zone of the cutter body and improve removal efficiency and reduce repair time through mechanical vibration assistance.

[0007] In a preferred embodiment, the flux used in S4 is a potassium fluoride-potassium fluoroborate composite flux, which has excellent high-temperature fluidity and wettability, and is particularly suitable for welding cemented carbide and high-temperature alloys.

[0008] In a preferred embodiment, the S3 employs a micro-tapered structure with a taper ratio controlled between 1:70 and 1:100. This utilizes a self-locking effect to increase the bonding force between the cutter head and the cutter body, thereby enhancing the impact and friction resistance after welding.

[0009] In a preferred embodiment, S5 is performed using a vacuum brazing furnace with a vacuum level controlled at ≤1×10Pa and a welding time of 15 to 25 minutes to ensure that the welding process is not affected by oxidation and that there are no defects such as pores or cracks after welding.

[0010] In a preferred embodiment, the heat treatment process in S6 is annealing, with the annealing temperature controlled between 300°C and 400°C and the holding time being 1 to 2 hours, which effectively eliminates the stress after welding and enhances the fatigue resistance of the tool.

[0011] In a preferred embodiment, the end face runout of the cutter head in S7 is no greater than 0.02mm, and the radius of the cutting edge fillet is controlled between 0.015mm and 0.03mm to ensure that the cutter has high-precision machining capabilities and a long service life.

[0012] In a preferred embodiment, the material of the cemented carbide cutting tip selected in S4 is tungsten-cobalt alloy or tungsten steel alloy, the selected cutting tip has a hardness of HRA90 or higher, and the contact surface between the cutting tip and the cutting body is optimized for microscopic morphology before assembly to improve the bonding force and wear resistance between the cutting tip and the cutting body.

[0013] In a preferred embodiment, the ultrasonic cleaning in S2 uses an ultrasonic device with a frequency of 20kHz to 40kHz, combined with a high-pressure water jet, and the cleaning fluid is a mixture of deionized water and organic solvent, to ensure that the welded surface is completely free of oil and oxides, thereby further improving the welding quality and stability.

[0014] In a preferred embodiment, the cooling process after heat treatment in S6 adopts forced air cooling or oil cooling, and the cooling rate is controlled between 5℃ / min and 10℃ / min to ensure that the tool cools down uniformly during the cooling process and prevent tool deformation or cracks caused by uneven cooling.

[0015] The inlay-type tool repair process provided by this invention has the following beneficial effects: 1. By combining various advanced technologies such as laser cutting, high-frequency induction heating, and vacuum brazing, the wear resistance, hardness, and impact resistance of repaired cutting tools are significantly improved. In particular, during the welding and heat treatment process, the base material of the cutting tool and the new cutting head are welded together with high precision to ensure that there are no cracks or pores at the weld, minimizing the performance degradation caused by repair. Through reasonable temperature control and cooling process, the surface of the repaired cutting tool is effectively strengthened, the overall hardness and durability of the cutting tool are greatly improved, its service life is extended, and the machining accuracy of the cutting tool can be effectively maintained.

[0016] 2. By adopting efficient cleaning and pretreatment processes such as ultrasonic cleaning and optical scanning inspection, the repaired tools can be put into production more quickly, reducing tool downtime and thus improving the operating efficiency of the production line. At the same time, due to the use of high-performance repair materials such as cemented carbide and coated alloys, even highly difficult tool repairs can be completed within a reasonable cost control range, reducing the expenses of tool replacement and purchasing new tools, and further optimizing the overall production cost. Attached Figure Description

[0017] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present invention and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained from these drawings without creative effort.

[0018] Figure 1 This is a process flow diagram provided by an embodiment of the present invention. Detailed Implementation

[0019] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, 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, 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.

[0020] Reference Figure 1 This invention provides a technical solution: an inlay-type tool repair process, comprising the following steps: S1: Removal of Damaged Cutting Heads: For severely damaged or worn cutting head sections on inlaid cutting tools, precise positioning is achieved using laser cutting combined with high-frequency induction heating technology. This minimizes the impact of the heat-affected zone on the tool body structure. Laser cutting ensures precise cutting lines and avoids deformation or damage to the tool body caused by high-temperature processing. High-frequency induction heating combined with mechanical vibration allows for safe removal of damaged cutting heads in a short time, avoiding overheating or stress concentration in the base material caused by traditional heating or mechanical methods. In step S1, laser cutting combined with high-frequency induction heating is used to reduce the heat-affected zone of the tool body. Mechanical vibration is used to assist in improving removal efficiency and reducing the repair process time. The method of removing the damaged tool head by combining laser cutting with high-frequency induction heating technology further reduces the time cost of the repair process and improves work efficiency. With the assistance of mechanical vibration, the removal efficiency is significantly improved. This not only avoids the problem of tool body deformation caused by high temperature, but also improves the accuracy and stability of the tool after repair through high-precision removal. The combination of laser cutting and high-frequency heating technology enables the tool head to complete high-precision removal in a short time. At the same time, mechanical vibration plays a role in relieving stress and reducing friction during the removal process, reducing the errors that may occur during the repair process.

[0021] Data table of blade removal methods Removal process time difference table S2: Cleaning the welding surface: A multi-step cleaning method combining mechanical grinding, ultrasonic cleaning and high-pressure water jet is used to thoroughly remove oil, oxides and residues from the welding surface of the tool body, avoiding any welding defects. After cleaning, the welding surface is treated with a high-temperature argon oxidizing protective flame, with the temperature controlled between 600℃ and 750℃ and the oxygen content controlled within ≤2%, to ensure that the welding surface has good activity and welding quality. The ultrasonic cleaning in S2 uses an ultrasonic device with a frequency of 20kHz to 40kHz, combined with a high-pressure water jet. The cleaning solution is a mixture of deionized water and organic solvent to ensure that the welded surface is completely free of oil and oxides, thereby further improving the welding quality and stability.

[0022] S3: Pre-processing assembly groove: The tool body inlay part is finely machined at the micron level. The inlay groove with a tapered or self-locking structure is formed by CNC machine tool. The groove depth is controlled between 3mm and 8mm, and the surface roughness Ra is controlled between 20μm and 35μm. By selecting high-precision tools, the groove wall is ensured to be flat and the angle is accurate. In addition, the groove size is detected by optical scanning technology to ensure that the dimensional deviation is controlled within 0.02mm, thereby enhancing the bonding force of the groove. The S3 employs a micro-tapered structure with a taper ratio controlled between 1:70 and 1:100. This utilizes a self-locking effect to increase the bonding force between the tool tip and the tool body, enhancing the post-weld impact and friction resistance. The taper ratio, controlled between 1:70 and 1:100, increases the self-locking effect between the tool tip and the tool body, improving the overall impact resistance after welding. The micro-tapered structure provides stronger fitting force during assembly, ensuring a firm bond between the tool tip and the tool body, thus enhancing the tool's durability. The taper structure is formed through precise CNC machining, utilizing the locking effect of its geometric shape to strengthen the bonding force between the tool tip and the tool body. Therefore, after welding, the contact surface between the tool tip and the tool body is more secure, preventing the tool tip from loosening or falling off during high-speed machining.

[0023] Differences in the structure of the blade insert groove Table of Inlay Groove Depth Difference S4: Select and assemble new cutting heads: Select cutting heads with high wear resistance and high hardness, such as cemented carbide, coated cemented carbide, or superhard materials, and coat the contact surface of the cutting head with high-temperature adhesive or customized flux. Through a meticulous inlay process, ensure that the new cutting head has no gaps in the assembly slot and fits precisely. Use a laser positioning system to monitor the position of the cutting head in real time to ensure that the positioning and docking accuracy of the cutting head is within the micron range. The flux used in S4 is a potassium fluoride-potassium fluoroborate composite flux, which has excellent high-temperature fluidity and wettability. It is particularly suitable for welding cemented carbide and high-temperature alloys. The material has extremely high wear resistance and hardness, and can maintain a stable working state under harsh processing conditions, effectively resisting the mechanical stress generated during tool use.

[0024] The material of the cemented carbide cutting tip selected in S4 is tungsten-cobalt alloy or tungsten steel alloy. The selected cutting tip has a hardness of HRA90 or higher, and the contact surface between the cutting tip and the cutting body is optimized for microscopic morphology before assembly to improve the bonding force and wear resistance between the cutting tip and the cutting body.

[0025] Table of Tool Head Assembly Precision Differences S5: Welding and Fixing: Vacuum brazing or argon-shielded welding technology is used to weld the cutter head and cutter body with silver-based brazing or high-temperature cobalt-based solder. The temperature is controlled between 750℃ and 950℃ to ensure that gas does not enter the welding area during the welding process, preventing oxidation and porosity. An automated welding robot is used to precisely control the welding path during welding to avoid human error. A high-precision temperature control system is used to adjust the welding temperature in real time during the welding process to ensure the stability of the welding. The S5 process employs a vacuum brazing furnace with a vacuum level controlled at ≤1×10Pa and a welding time of 15 to 25 minutes. This ensures that the welding process is unaffected by oxidation, resulting in no defects such as porosity or cracks after welding. Using a vacuum brazing furnace ensures a vacuum environment during the welding process, preventing the entry of oxidizing gases and effectively avoiding the formation of porosity. Controlling the vacuum level and welding time ensures optimal welding quality, further improving the strength and stability of the repaired tool. Vacuum brazing technology, by heating under low pressure, avoids the reaction between oxygen in the air and the welding material, reducing the probability of defects.

[0026] Welding temperature control range diagram Chart of differences in welding methods Welding Time Difference Table S6: Heat Treatment and Cooling: After welding, the entire tool undergoes a heat treatment process to eliminate residual welding stress and improve tool hardness. The annealing temperature is controlled between 350℃ and 400℃, and the holding time is controlled between 1 and 2 hours. The cooling process uses oil cooling or air cooling to ensure that the cooling rate is within the specified range, avoiding rapid cooling that could cause hot cracks, and ensuring the stability and toughness of the tool structure. The heat treatment process in S6 is annealing, with the annealing temperature controlled between 300℃ and 400℃ and the holding time being 1 to 2 hours. This effectively eliminates the stress after welding and enhances the fatigue resistance of the tool. Annealing is used to eliminate the stress after welding, giving the tool higher fatigue resistance. The temperature and time control during the annealing process can effectively reduce the internal stress of the material and improve the toughness and durability of the tool.

[0027] The cooling process after heat treatment in S6 adopts forced air cooling or oil cooling, and the cooling rate is controlled between 5℃ / min and 10℃ / min to ensure that the tool cools down evenly during the cooling process and prevent tool deformation or cracks caused by uneven cooling.

[0028] Annealing time difference table S7: Precision Finishing and Inspection: The welded tool undergoes high-precision grinding and fine-tuning to ensure that the tool tip geometry and cutting edge accuracy meet design requirements. Cutting edge accuracy is controlled within ±0.01mm, end face runout is no greater than 0.015mm, and the tool tip corner radius is controlled between 0.01mm and 0.03mm. The welded area is inspected using a scanning electron microscope (SEM) to ensure the weld is free of microcracks, porosity, and other defects. Finally, an automated flaw detection system performs comprehensive inspection of the tool to ensure that the repaired tool meets high precision and high strength requirements.

[0029] In S7, the end face runout of the cutter head is no greater than 0.02mm, and the cutting edge radius is controlled between 0.015mm and 0.03mm to ensure high-precision machining capability and long service life. Precision dressing ensures that the cutter head's geometry and cutting edge accuracy meet design requirements, further improving machining precision. Fine-tuning the cutting edge radius ensures smoother workpiece entry during cutting, reducing friction and extending tool life. Precision dressing employs high-precision grinding technology to ensure the cutting edge geometry meets design requirements, optimizing the tool's cutting performance.

[0030] Cutting edge precision difference table End face runout accuracy difference table The above process begins with a comprehensive inspection of the damaged object to determine the specific location and extent of the damage, allowing for the selection of appropriate repair methods and materials. Before starting repairs, the damaged area must be thoroughly cleaned to remove surface dust, oil stains, rust, or other impurities, ensuring proper adhesion of the repair material. Subsequently, based on the material and intended use of the damaged object, suitable repair materials are selected. During repair, cracks and holes need to be filled or bonded, and reinforcements may be added if necessary to ensure structural integrity and strength. After the material is filled, a period of time is usually required for it to dry or cure. After drying, surface treatments such as sanding and finishing are necessary to ensure the repaired area matches the appearance of the original object. If needed, painting, coloring, or protective treatments can be applied to enhance its aesthetics and usability. Finally, the repair results are inspected, including tests on appearance, strength, and functionality, to ensure the repaired item can be used normally and has a good lifespan. The entire repair process requires meticulous operation and patience, with the aim of restoring the damaged item to its original function and appearance, extending its service life, and reducing replacement costs and resource waste.

Claims

1. An inlay-type tool repair process, characterized in that, Includes the following steps: S1: Remove damaged cutting head: Precisely locate the damaged or severely worn cutting head on the inlaid cutting tool, and use laser cutting combined with high frequency induction heating technology to reduce the impact of the heat-affected zone on the structure of the cutting tool body; S2: Cleaning the welding surface: Using a multi-step cleaning method that combines mechanical grinding, ultrasonic cleaning and high-pressure water jetting, oil, oxides and residues on the welding surface of the blade are thoroughly removed to avoid any welding defects; S3: Pre-processing assembly groove: The tool body inlay part is finely machined at the micron level, and an inlay groove with a tapered or self-locking structure is formed by CNC machine tool processing; S4: Select and assemble new cutting tips: Select cutting tips with high wear resistance and high hardness, such as cemented carbide, coated cemented carbide, or superhard materials, and coat the contact surface of the cutting tips with high-temperature adhesive or customized flux. S5: Welding and fixing: Vacuum brazing or argon-protected welding technology is used to weld the cutter head and cutter body with silver-based brazing or high-temperature cobalt-based solder. The temperature is controlled between 750℃ and 950℃ to ensure that the gas does not enter the welding area during the welding process, thus preventing oxidation and the formation of pores. S6: Heat treatment and cooling: After welding, the entire tool is subjected to heat treatment to eliminate residual welding stress and increase tool hardness. S7: Precision Dressing and Inspection: High-precision grinding and fine-tuning of the welded cutting tools to ensure that the geometry and cutting edge accuracy of the tool head meet the design requirements.

2. The inlay-type tool repair process according to claim 1, characterized in that, The process in S1 combines laser cutting with high-frequency induction heating to reduce the heat-affected zone of the cutter body and improve removal efficiency and reduce repair time through mechanical vibration assistance.

3. The inlay-type tool repair process according to claim 2, characterized in that, The flux used in S4 is a potassium fluoride-potassium fluoroborate composite flux, which has excellent high-temperature fluidity and wettability, and is particularly suitable for welding between cemented carbide and high-temperature alloys.

4. The inlay-type tool repair process according to claim 3, characterized in that, The S3 adopts a micro-tapered structure with a taper ratio controlled between 1:70 and 1:

100. It utilizes a self-locking effect to increase the bonding force between the cutter head and the cutter body, thereby enhancing the impact and friction resistance after welding.

5. The inlay-type tool repair process according to claim 4, characterized in that, The S5 process uses a vacuum brazing furnace with a vacuum level controlled at ≤1×10Pa and a welding time of 15 to 25 minutes to ensure that the welding process is not affected by oxidation and that there are no defects such as pores or cracks after welding.

6. The inlay-type tool repair process according to claim 5, characterized in that, The heat treatment process in S6 is annealing, with the annealing temperature controlled between 300°C and 400°C and the holding time being 1 to 2 hours. This effectively eliminates the stress after welding and enhances the fatigue resistance of the cutting tool.

7. The inlay-type tool repair process according to claim 6, characterized in that, In S7, the end face runout of the cutter head is no more than 0.02mm, and the radius of the cutting edge fillet is controlled between 0.015mm and 0.03mm to ensure that the cutter has high-precision machining capabilities and a long service life.

8. The inlay-type tool repair process according to claim 6, characterized in that, The material of the cemented carbide cutting tip selected in S4 is tungsten-cobalt alloy or tungsten steel alloy. The selected cutting tip has a hardness of HRA90 or higher, and the contact surface between the cutting tip and the cutting body is optimized for microscopic morphology before assembly to improve the bonding force and wear resistance between the cutting tip and the cutting body.

9. The inlay-type tool repair process according to claim 6, characterized in that, The ultrasonic cleaning in S2 uses an ultrasonic device with a frequency of 20kHz to 40kHz, combined with a high-pressure water jet. The cleaning solution is a mixture of deionized water and organic solvent to ensure that the welded surface is completely free of oil and oxides, thereby further improving the welding quality and stability.

10. The inlay-type tool repair process according to claim 6, characterized in that, The cooling process after heat treatment in S6 adopts forced air cooling or oil cooling, and the cooling rate is controlled between 5℃ / min and 10℃ / min to ensure that the tool cools down evenly during the cooling process and prevent tool deformation or cracks caused by uneven cooling.

Images