Composite Cutting Member Welding for Hard Edge and Tough Body
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional cutting members face a trade-off between toughness of the support portion and hardness/abrasion resistance of the cutting edge, resulting in a short service life, as using high hardness materials compromises toughness and vice versa.
Innovation Solution
A cutting member is manufactured using a combination of martensitic stainless steel for the support portion and high-speed or alloy tool steel for the cutting edge, welded together with high energy density beams like laser or electron beams, followed by heat treatment to achieve a strong, hole-free weld with optimized metallographic structures for enhanced tensile strength and hardness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a material with high hardness is used to improve the hardness of the cutting edge, then the service life of the cutting edge is extended, but the toughness of the body is poor so it is easily broken during use
Solution Approach 1:
The cutting member is divided into two distinct portions: a body portion made of material with good toughness and a cutting edge portion made of material with high hardness. This segmentation allows each portion to have optimized properties for its specific function, resolving the contradiction between overall toughness and cutting edge hardness.
Solution Approach 2:
The cutting member uses a composite structure combining two different metal materials - one for the body (prioritizing toughness) and one for the cutting edge (prioritizing hardness). This composite approach enables the final product to exhibit both high toughness in the body and high hardness at the cutting edge simultaneously.
2Reliability
If a material with good toughness is used to improve the toughness of the body, then the resistance to breaking is improved, but the hardness of the cutting edge is deteriorated so that the abrasion resistance is reduced
Solution Approach 1:
The cutting member is divided into two distinct portions: a body portion made of material with good toughness and a cutting edge portion made of material with high hardness. This segmentation allows each portion to have optimized properties for its specific function, resolving the contradiction between overall toughness and cutting edge hardness.
Solution Approach 2:
The cutting member uses a composite structure combining two different metal materials - one for the body (prioritizing toughness) and one for the cutting edge (prioritizing hardness). This composite approach enables the final product to exhibit both high toughness in the body and high hardness at the cutting edge simultaneously.
3Reliability
If an intermediate performance material is used to balance toughness and hardness, then both properties achieve moderate levels, but neither reaches the best effects
Solution Approach 1:
The cutting member is divided into two distinct portions: a body portion made of material with good toughness and a cutting edge portion made of material with high hardness. This segmentation allows each portion to have optimized properties for its specific function, resolving the contradiction between overall toughness and cutting edge hardness.
Solution Approach 2:
The cutting member uses a composite structure combining two different metal materials - one for the body (prioritizing toughness) and one for the cutting edge (prioritizing hardness). This composite approach enables the final product to exhibit both high toughness in the body and high hardness at the cutting edge simultaneously.
4Ease of manufacture
If conventional welding methods are used to join different metal materials, then the manufacturing process is simple, but the weld contains holes and has poor tensile strength
Solution Approach 1:
Conventional welding methods are replaced with high energy density beam welding (laser, electron beam, or ion beam welding). This substitution eliminates the formation of holes in the weld and significantly improves tensile strength at the welding site, while the automated nature of beam welding maintains manufacturing efficiency.
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 method results in a cutting member with high toughness and high hardness/abrasion resistance, significantly extending the service life beyond conventional limits, with the weld connection being strong and durable, and the cutting edge maintaining its effectiveness.
Implementation Method 1
welding the first side of the first metal material and the second side of the second metal material with high energy density beam, and the above-described third portion is formed at the welding site
Implementation Method 2
the above-described high energy density beam welding is laser, electron beam or ion beam welding
Implementation Method 3
the above-described high energy density beam welding is laser, electron beam or ion beam welding
Implementation Method 4
obtaining a cutting member blank after welding, and performing heat treatment on the cutting member blank
Data Source
AI summary
A method of manufacturing a cutting member include cutting a first metal material to form a first portion of the cutting member; cutting second metal material to form a second portion of the cutting member, wherein a first edge of the second portion has at least two line segments, a curve formed by the at least two line segments being mathematically continuously differentiable; welding the first portion and the second portion together; raising the cutting member blank to a first temperature at a first rate and holding raising the cutting member blank from the first temperature to a second temperature at a second rate lower than the first rate and holding, and raising the cutting member blank from the second temperature to a third temperature at a third rate not higher than the second rate and holding.