Band Saw Blade Polishing Sequence for Accurate Tooth Tip Welding
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Solution Overview
Problem
The manufacturing method for ring-shaped band saw blades often results in shape accuracy issues and surface quality deterioration due to thermal distortion and unevenness in the welding process, leading to poor cut surface quality.
Innovation Solution
A polishing apparatus and method that uses a combination of drive and driven wheels with guide sections and inclined grindstones to precisely polish the inner and outer surfaces of the band saw blade, ensuring uniform tension and accurate shaping of the cutting tip, thereby reducing distortion and surface unevenness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the band saw blade is clamped with a vise and polished using tooth tip and end portion as positioning references, then the polishing operation can be performed, but shape accuracy of tooth tips decreases due to thermal distortion in the body part
Solution Approach 1:
The patent applies preliminary action by performing the polishing operation before the resistance welding that causes thermal distortion. The body part is polished while in its undistorted state, and then the ring shape is formed by welding the opposite ends. This sequence ensures that the polishing references (tooth tip and end portion) maintain their original positions and shapes, preventing the shape accuracy degradation that would occur if polishing were performed after welding-induced distortion.
Solution Approach 2:
The patent inverts the conventional manufacturing sequence by performing polishing before ring-shape formation through welding, rather than after. This reversal of the process order allows the body part to be polished in its stable, undistorted state, eliminating the problem of thermal distortion affecting tooth tip shape accuracy during the polishing operation.
2Ease of manufacture
If the opposite ends of the band saw blade are joined by resistance welding to form a ring shape, then the ring-shaped band saw blade is formed, but bulging occurs in the joined part causing surface unevenness
Solution Approach 1:
The patent applies preliminary action by performing the polishing operation before the resistance welding that causes thermal distortion. The body part is polished while in its undistorted state, and then the ring shape is formed by welding the opposite ends. This sequence ensures that the polishing references (tooth tip and end portion) maintain their original positions and shapes, preventing the shape accuracy degradation that would occur if polishing were performed after welding-induced distortion.
Solution Approach 2:
The patent extracts the polishing operation from the sequence of operations that follows welding, and performs it separately before welding. By separating the polishing step from the post-welding process, the harmful effects of thermal distortion and bulging on polishing accuracy are eliminated, as the polishing is performed on the undistorted body part.
3Shape
If the joined part with bulging is cut with a grinder to flatten the surface, then the ring shape is corrected, but slight unevenness remains causing orbiting tool marks in cut surface
Solution Approach 1:
The patent applies preliminary action by performing the polishing operation before the resistance welding that causes thermal distortion. The body part is polished while in its undistorted state, and then the ring shape is formed by welding the opposite ends. This sequence ensures that the polishing references (tooth tip and end portion) maintain their original positions and shapes, preventing the shape accuracy degradation that would occur if polishing were performed after welding-induced distortion.
Solution Approach 2:
The patent converts the potential harm of welding-induced distortion and surface unevenness into a benefit by performing polishing before welding. Instead of trying to remove unevenness after welding (which leaves residual defects), the polishing is performed on the undistorted body part, ensuring that no orbiting tool marks are generated during subsequent cutting operations.
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
The solution effectively enhances the shape accuracy of tooth tips and reduces surface irregularities, resulting in improved cut surface quality and prevention of orbiting tool marks during cutting.
Implementation Method 1
the joined part is polished with a grindstone
Implementation Method 2
joining opposite ends of a band saw blade by flash butt welding that is one type of resistance welding
Data Source
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AI summary
A ring forming step includes welding opposite ends of a band saw blade (1) including a body part (1a) having a band shape, and a tooth part (1b) including a plurality of teeth formed on one side part of the body part, to form a ring shape. A polishing step includes polishing an inner surface (14A), an outer surface (14B), and an end face (13) on a side opposite to the tooth part in the ring-shaped band saw blade (1E) subjected to the ring formation. A tip tooth tip forming step includes positioning, after the polishing step, the ring-shaped band saw blade subjected to the ring formation by use of one of the inner surface and the outer surface, and the end face as references, joining a cutting tip (15) to tooth tips of the plurality of teeth by welding, and polishing the joined cutting tip to form a tooth tip shape.