Cutter Blade Joint Design for Brazing-Free Fusion Welding
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Solution Overview
Problem
The existing method for joining a cutting edge part to a base metal part by brazing is costly and prone to damage during the finishing process, leading to reduced yield.
Innovation Solution
A cutter blade design with a cutting edge part and a base metal part joined by forming a film over the joint surface using plating or thermal spraying, followed by solidifying a molten material to create a detected cutting edge component and under-detection-limit part, allowing for direct fusion or diffusion joining without brazing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If brazing is used to join the cutting edge part to the base metal part, then the joining strength is improved, but the manufacturing cost increases and the risk of damage during finishing increases
Solution Approach 1:
The invention changes the joining method from brazing to direct fusion welding by controlling the chemical composition parameters. Specifically, the base metal part is designed with carbon content of 0.05-0.20% and silicon content of 0.03-0.15%, which enables direct fusion welding without brazing, thereby reducing manufacturing cost while maintaining joining strength
Solution Approach 2:
The invention extracts the brazing process from the manufacturing workflow and replaces it with direct fusion welding. By removing the intermediate brazing step and its associated finishing operations, the manufacturing cost is reduced and the risk of damage to cutting edge parts is eliminated
2Strength
If brazing is used to join the cutting edge part to the base metal part, then the joining strength is improved, but the yield decreases due to damage during finishing
Solution Approach 1:
The invention changes the material composition parameters of the base metal part to enable direct fusion welding. The carbon content (0.05-0.20%) and silicon content (0.03-0.15%) are specifically controlled to achieve weldability without brazing, eliminating the finishing step that causes damage and improves yield
Solution Approach 2:
The invention converts the potential harm of direct welding (which could damage the cutting edge) into a benefit by using controlled composition parameters. The specific carbon and silicon ranges ensure that direct fusion welding produces a strong joint without requiring damaging finishing operations, thus improving yield
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
This method reduces manufacturing costs and improves yield by preventing damage to the cutting edge and base metal parts, while eliminating the need for brazing and its associated processes.
Implementation Method 1
forming a film from a film forming material over at least a predetermined joint surface of a cutting edge part by plating or thermal spraying
Implementation Method 2
forming a film from a film forming material over at least a predetermined joint surface of a cutting edge part by plating or thermal spraying
Implementation Method 3
solidifying the molten material and thereby joining the base metal part to the joint surface of the cutting edge part
Implementation Method 4
the step of joining the base metal part to the joint surface is performed so that: the base metal part includes, in a vicinity of the joint surface, a cutting edge component-detected part
Data Source
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AI summary
A cutter blade (1) according to an embodiment comprises a cutting edge portion (20) which slides along a plate surface (204) of a die plate (201) to cut a material (206) extruded onto the plate surface (204) from a hole (205) formed in the plate surface (204), and a base metal portion (10) joined to a joining surface (25) of the cutting edge portion (20), wherein: the base metal portion (10) includes, in the vicinity of a joining surface (15), a cutting edge component detected part (10A) in which a cutting edge component, which is a constituent component of a cutting edge material included in the cutting edge portion (20), has been detected; the base metal portion (10) includes, inside the base metal portion (10), a cutting edge component detection-limit-or-lower part (10B) in which a concentration of the cutting edge component is equal to or less than a detection limit; and the cutting edge component detection part (10A) includes a part in which the concentration of the cutting edge component decreases with decreasing distance from the cutting edge component detection-limit-or-lower part (10B).