Internal Spline Remanufacturing by Laser Cladding in Deep Bores
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Solution Overview
Problem
Conventional methods are inadequate for repairing internal spline components due to the restricted space and risk of overheating in the bore, making it difficult to restore the internal geometry effectively.
Innovation Solution
A method involving the removal of worn internal geometry to a pre-cladding diameter, followed by laser cladding in multiple layers, and subsequent machining to produce a remanufactured internal geometry, which allows for the creation of a functional internal spline component.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional welding methods are used to repair internal splines, then material can be added to restore worn surfaces, but the restricted space and heat accumulation cause overheating of the inner surfaces
Solution Approach 1:
The patent replaces conventional welding (thermal process) with laser cladding (precise energy beam process). The laser cladding process allows for controlled material deposition with minimal heat affected zone, solving the overheating problem while restoring the internal spline geometry accurately.
Solution Approach 2:
The patent changes the thermal parameters of the repair process by using laser cladding instead of conventional welding. This involves controlling laser power, scanning speed, and layer thickness to maintain optimal temperature levels during material deposition, preventing overheating while achieving precise geometric restoration.
2Ease of repair
If additional material is welded to external spline teeth, then worn surfaces can be restored, but the process cannot be applied to internal splines due to restricted space
Solution Approach 1:
The patent replaces conventional welding equipment with laser cladding equipment that can access restricted internal spaces. The laser beam and cladding material delivery system are designed to reach into the bore and deposit material on internal spline surfaces, making repair feasible where conventional methods fail.
Solution Approach 2:
The patent applies material deposition in multiple sequential layers rather than attempting to restore all wear in a single operation. This layered approach allows the repair process to navigate restricted spaces effectively, with each layer building upon the previous one to gradually restore the internal spline geometry.
3Force
If the bore diameter is considerably longer than the diameter, then the component can transmit large torques, but damage or wear to the internal geometry becomes difficult to repair
Solution Approach 1:
The patent uses laser cladding technology that can deliver material precisely to deep internal surfaces through the bore. The laser beam's ability to travel through the restricted space and deposit material layer-by-layer makes it possible to repair the internal spline geometry in long-bore components that would be inaccessible to conventional welding equipment.
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 enables the effective remanufacturing of internal spline components by avoiding overheating and ensuring a precise, stress-compatible cladding that maintains the component's functionality and longevity.
Implementation Method 1
cladding the inner surface in a plurality of layers by laser cladding to produce a cladded surface
Data Source
AI summary
A remanufactured internal spline component includes an inner surface defining a cylindrical bore and a remanufactured internal geometry on the inner surface. The internal geometry has a maximum diameter and a minimum diameter. The remanufactured internal geometry is created by removing a worn internal geometry to a pre-cladding diameter, cladding the inner surface in a plurality of layers by laser cladding to produce a cladded surface, and machining the cladded surface to produce the remanufactured internal geometry.