Cold-weld Burr Removal System Using Shearing Force
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Cold-welding processes produce excess material in the form of cold-weld burrs, which can be hazardous and hinder efficient storage due to their sharp edges and increased width, necessitating an effective removal method.
Innovation Solution
A cold-weld burr removal system comprising a clamping block, a removal block, a cutting head insert, and a linear actuator, where the cutting head insert with a cutting edge removes the burr via a shearing force while the rod remains stationary, and the burr is collected in a burr collector.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If cold welding is performed to join metal parts, then the parts are bonded together through compression, but cold-weld burrs are produced that create safety hazards and storage inefficiency
Solution Approach 1:
The patent extracts and removes the harmful cold-weld burr from the rod surface using a cutting head that applies a shearing force to separate the burr material from the base metal, thereby eliminating the safety hazard while preserving the joint strength
Solution Approach 2:
The cutting head applies a localized shearing force only to the burr region rather than the entire rod, selectively removing the harmful sharp edges while leaving the rest of the rod and its cold-weld joint intact and undamaged
2Shape
If cold-weld burrs are not removed, then the rod maintains its original dimensions, but storage efficiency is reduced due to increased width from protruding burrs
Solution Approach 1:
The cutting head removes the protruding burr material that causes increased rod width, restoring the rod to its original dimensional profile and enabling more compact, efficient storage arrangements
3Object-generated harmful factors
If a cutting head is used to remove burrs, then burr removal is achieved, but the system complexity increases with multiple components
Solution Approach 1:
The cutting head is integrated with the existing cold-welding apparatus, combining the burr removal function with the joint formation process in a single integrated system rather than requiring a separate standalone burr removal device
Solution Approach 2:
The cutting head serves multiple functions: it removes cold-weld burrs, maintains rod dimensional accuracy, and can be applied to various rod sizes and materials, providing a versatile solution that justifies the added component
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 system safely and efficiently separates and removes cold-weld burrs, enhancing safety and allowing for more compact storage by eliminating hazardous edges and excess material.
Implementation Method 1
The cutting edge can remove at least some of the cold-weld burr from the rod via a shearing force that is created when the removal block moves away from the clamping block via the linear actuator
Data Source
AI summary
A cold-weld burr removal system is disclosed according to various embodiments. The cold-weld burr removal system can include a clamping block having a clamping passage that extends along an alignment axis, and a removal block having a guide passage alignment axis centered about the alignment axis. The removal block can define a burr receiving chamber. The system also can include a cutting head insert having a cutting portion and a cutting passage. The cutting head insert can removably attach to the removal block and the cutting portion can protrude into the burr receiving chamber. The system can include a linear actuator that connects the clamping block to the removal block. The linear actuator can move the removal block in a direction along the alignment axis to increase a separation distance between the clamping block and the removal block when a linear actuation initiator initiates movement of the linear actuator.