Laser-Clad Anvil Roll Protrusions Without Post-Machining
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Solution Overview
Problem
The current laser cladding process for manufacturing industrial tools like anvil rolls requires post-machining steps to achieve required tolerances, adding extra expense.
Innovation Solution
A method involving laser cladding to form protrusions with conical or frustro-conical shapes on a cylindrically-shaped body, using metallic materials, ensuring precise fusion and synchronization of laser pulses and powder application to eliminate the need for further machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If laser cladding process is used to add metal components, then productivity and adaptability are improved, but manufacturing precision deteriorates due to inability to achieve required tolerances without post-machining
Solution Approach 1:
The patent applies preliminary action by pre-calculating and pre-compensating for laser deposition characteristics (heat-affected zone, shrinkage, distortion) during the digital modeling phase. The CAD system incorporates compensation algorithms that anticipate dimensional deviations and correct them in advance, allowing the additive process to directly achieve final tolerances without post-machining.
Solution Approach 2:
The patent implements feedback through closed-loop control systems that monitor laser cladding parameters in real-time and adjust deposition conditions accordingly. Sensors measure actual protrusion dimensions during construction, and the system automatically compensates for deviations by modifying subsequent deposition parameters, ensuring final dimensional accuracy matches design requirements.
2Manufacturing precision
If post-machining steps are added to achieve required tolerances, then manufacturing precision is improved, but productivity decreases and costs increase
Solution Approach 1:
The patent extracts and eliminates the post-machining operations from the manufacturing process entirely. By integrating compensation algorithms directly into the additive manufacturing workflow, the system achieves final dimensional accuracy during the deposition phase itself, removing the need for separate machining, grinding, or spark erosion operations that would extend production time.
Solution Approach 2:
The patent merges the dimensional control function into the additive manufacturing process itself. Instead of treating precision achievement as a separate post-processing step, the system combines real-time monitoring, adaptive parameter adjustment, and compensation strategies within the laser cladding operation, unified the deposition and precision control functions into a single integrated process.
3Device complexity
If conventional laser cladding is used without synchronized control, then device complexity is reduced, but manufacturing precision deteriorates due to lack of coordination between laser pulses and powder application
Solution Approach 1:
The patent applies feedback through synchronized control systems that coordinate laser pulse timing with powder feed rates and gas stream parameters. Sensors monitor the deposition process and provide real-time data to the control system, which adjusts parameters to maintain consistent protrusion geometry, ensuring accurate conical or frustro-conical shapes are achieved reliably.
Solution Approach 2:
The patent implements periodic action through rhythmically synchronized laser pulsing and powder application. The system uses periodic laser pulses coordinated with periodic powder feeding cycles, creating a rhythmic deposition pattern that builds uniform protrusions layer by layer, with each cycle contributing to the final conical or frustro-conical geometry.
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
Achieves high dimensional accuracy of protrusions, eliminating the need for further machining steps and ensuring smooth surfaces, thereby reducing production costs.
Implementation Method 1
fusing, by applying power from a laser source, the one or more metallic materials to the outer circumferential surface of the body to form a plurality of protrusions
Implementation Method 2
Laser cladding, or laser metal deposition, is an additive production process that uses a laser beam to form a pool of melted metal on the surface of a metallic substrate into which metal powder is injected
Data Source
AI summary
The present invention relates to a method for making an anvil roll, the method comprising the steps of: providing a cylindrically-shaped body consisting of a first material, wherein the first material is selected from the group consisting of: an iron alloy, an aluminum alloy, and a titanium alloy, and wherein the body comprises an outer circumferential surface; adding one or more metallic materials in the form of powder; and fusing, by applying power from a laser source, the one or more metallic materials to the outer circumferential surface of the body to form a plurality of protrusions having a conical or frustro-conical shape comprising tapering sides, from a broader base at the outer circumferential surface tapering outwardly towards a narrower tip or having a cylindrical shape.