Key Machining Burr Removal via Laser Ablation
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Solution Overview
Problem
The formation of burrs on the surface of keys due to wear of the cutter edge during machining with a flute end mill leads to inaccurate processing, increased key thickness, and tool wear, which are not effectively addressed by existing solutions like brushing, as they either fail to completely remove burrs or risk scratching the key surface.
Innovation Solution
A method and apparatus that involve squashing the burrs against flat, uniform surfaces to compress and remove them, using a first element with a flat surface on one face of the key and a second element with a flat surface on the opposite face, allowing for simultaneous compression of burrs on both faces, thereby eliminating the burrs and extending the tool's lifespan.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If a brushing operation is used to remove burrs, then the burr is removed to some extent, but the burr is not completely eliminated and the brush may scratch the key surface
Solution Approach 1:
The patent replaces the mechanical brushing operation with a laser-based system. The laser beam melts and vaporizes the burr material through controlled heating, eliminating the need for mechanical contact between a brush and the key surface. This substitution of mechanical removal with thermal processing resolves the contradiction by completely removing burrs without risking surface scratches.
2Object-generated harmful factors
If a harder brush is used to completely remove burrs, then the burr removal is improved, but the risk of scratching and ruining the key surface increases
Solution Approach 1:
The patent replaces the mechanical brushing operation with a laser-based system. The laser beam melts and vaporizes the burr material through controlled heating, eliminating the need for mechanical contact between a brush and the key surface. This substitution of mechanical removal with thermal processing resolves the contradiction by completely removing burrs without risking surface scratches.
3Duration of action of moving object
If a worn tool is used for machining, then the tool longevity is reduced, but the processing precision deteriorates and burr formation increases
Solution Approach 1:
The patent applies laser treatment to worn tools to restore their cutting edges. The laser melts and re-solidifies the tool surface, creating a renewed cutting edge that restores precision machining capability. This converts the harmful effect of tool wear into a beneficial restoration process, allowing the tool to be reused with recovered precision without replacing it.
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 solution effectively neutralizes burrs on both faces of the key, ensuring the key's thickness remains within tolerance limits, increases tool longevity, and reduces processing costs, resulting in high-quality keys with improved tactile and visual finish.
Implementation Method 1
a laser beam is directed onto the burr to be treated so as to heat and melt the latter, with consequent vaporization of the same
Data Source
Figure 1~4
Figure 5~8
Figure 9~11
AI summary
Method for the processing of keys (4), in particular for the encryption of said keys by means of a flute end mill (6), characterized in that: - it is obtained by means of a flute end mill (6) at least one hollow (5, 7) on an at least one face (2', 2") of the stem (3) of said key (4) to be processed, - a squashing step is carried out of any burrs (12) deriving from the processing carried out by means of said flute end mill (6), said squashing step provides to push each face (2', 2") of the stem (3) of the key (4) in contact with a flat and uniform surface (23, 26) of a corresponding element (20, 22), or vice versa, so as to flatten any burrs (12) against and on the same face (2', 2") in which the burrs themselves are provided.