Composite Mandrel Resurfacing for Same-Diameter Rod Repair
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Solution Overview
Problem
The existing rod processing and manufacturing technologies face challenges in repairing and reusing rods with partial damages, leading to high manufacturing costs, low utilization rates, and short service lives due to weakened structural strength, surface hardness, and smoothness issues, as well as difficulties in connecting short rods into long ones without altering diameters.
Innovation Solution
A composite rod processing method involving a main body and auxiliary body connected through inner and outer threads, with an alloy resurfacing welding layer, high-temperature annealing, grinding, chromium electroplating, and inspection to maintain diameter and strength, allowing for repair and extension of rod length while ensuring surface hardness and smoothness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If rods are made longer than 10m to meet processing requirements, then the processing quality of seamless steel pipes is improved, but the difficulty of processing and manufacturing increases
Solution Approach 1:
The rod is divided into a main body and an auxiliary body that can be connected through threading. This segmentation allows the rod to be manufactured in manageable sections and assembled to achieve the required length, solving the processing difficulty while maintaining the necessary processing quality.
Solution Approach 2:
The invention transitions from a single-piece rod to a modular assembled structure, adding the dimension of connectability. This allows length extension through assembly rather than manufacturing one continuous piece, reducing processing difficulty while achieving the required length and quality.
2Manufacturing precision
If carbonized layers and damages are removed from rod surfaces to repair damages, then the surface quality is improved, but the rod diameter decreases and service life is shortened
Solution Approach 1:
Instead of removing damaged surface layers, the invention applies a resurfacing welding layer locally on the rod surface. This maintains the original rod diameter while restoring surface quality, allowing multiple repairs without reducing the rod dimensions and thus extending service life.
Solution Approach 2:
The invention uses a composite structure with a base rod material and a resurfacing welding layer. This composite approach allows the surface to be repaired and restored multiple times without removing material, maintaining diameter and extending service life while ensuring surface quality.
3Ease of manufacture
If connecting mandrels are installed in the center of rod ends for connection, then the structure connection is simplified, but the anti-flex strength at connected positions is weakened
Solution Approach 1:
The invention removes the connecting mandrel from the connection structure, using direct threading between rod ends instead. This eliminates the weak point introduced by mandrels while maintaining connection simplicity through the threaded interface, thereby improving anti-flex strength at connected positions.
4Reliability
If rods are repaired by removing damaged surface layers, then surface damages are eliminated, but material utilization rate decreases due to diameter reduction
Solution Approach 1:
The resurfacing welding layer is applied locally on the rod surface rather than removing material. This maintains the original rod diameter and maximizes material utilization while ensuring surface integrity, allowing repeated repairs without material loss.
Solution Approach 2:
Instead of discarding material by removing damaged layers, the invention recovers the surface by applying a welding layer. This approach maintains material volume and diameter, improving material utilization rate while restoring surface integrity for continued use.
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 extends the service life of rods, reduces processing costs, and enhances mechanical strength and surface properties, enabling efficient repair and reuse of rods under the same diameter, thus improving material utilization and manufacturing efficiency.
Implementation Method 1
resurfacing welding of high-temperature and wear-resistant alloy for the entire rod
Implementation Method 2
high-temperature annealing after resurfacing welding
Implementation Method 3
electroplating chromium for the entire rod
Data Source
AI summary
This invention relates to a composite mandrel and its processing technology, including: processing, connection, welding, alloy overlaying, tempering after overlaying, polishing, chrome plating etc., on the whole and auxiliary body of mandrel. The composite mandrel includes a plurality of main and auxiliary bodies, the surface is overlaid with high temperature resistant, wear resistant, thermal fatigue resistant alloy, polished, and chrome plated, obtaining the characteristics of wear resistance, thermal fatigue resistance and high temperature resistance. The whole process not only increase the strength, toughness and hardness of the mandrel, improves its service quality, but also prolong the service life. With simple structure and reliable quality, composite mandrel can meet the requirements of different running condition. Whether for new-made mandrels, or for equal diameter renewal of failed mandrels, composite mandrel process can show its advantages of suitable material quantity, energy saving, consumption reduction, and production cost reduction.