Laser Cladding Thread Forming Tools Hollow Tubular Support
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Solution Overview
Problem
Current methods for making tools for forming threads on cylindrical bodies via plastic deformation result in tools with low mechanical strength, high wear rates, and increased production costs due to the use of solid metal bodies and inefficient manufacturing processes.
Innovation Solution
A method involving a hollow tubular support body made of high-hardness metal, coated with a laser-formed bead of metal powders and inert gas to create a spiral rib with controlled deposition and subsequent grinding to achieve the desired thread profile, allowing for tools with enhanced mechanical characteristics and extended lifespan.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If tools are made from solid metal bodies with milling processes, then the central hole and spiral rib can be formed, but the rib lacks high mechanical strength and suffers from quick wear
Solution Approach 1:
The tool combines a solid metal support body with a laser-deposited metal powder coating layer, creating a composite structure where the coating provides enhanced hardness and wear resistance while the support body provides structural strength. This composite approach resolves the contradiction by integrating materials with complementary properties.
Solution Approach 2:
The traditional mechanical milling process is replaced with laser-based deposition and forming. The laser beam melts and deposits metal powders to form the rib structure, eliminating the cutting discontinuities caused by milling and creating a continuous, high-strength rib with superior wear resistance.
2Ease of manufacture
If solid metal bodies are used as starting material, then tools can be manufactured, but production costs increase and material availability is limited
Solution Approach 1:
A hollow tubular support body is used as the starting material instead of solid metal blocks. This preliminary preparation reduces material consumption and allows the tool to be manufactured from readily available hollow metal tubes, improving both ease of manufacture and reducing waste.
Solution Approach 2:
The manufacturing process transitions from removing material (milling) to adding material (laser deposition). By changing the fundamental approach from subtractive to additive manufacturing, the process enables use of hollow starting materials and significantly reduces material consumption while lowering production costs.
3Strength
If traditional milling processes are used to form the spiral rib, then the thread profile can be created, but the rib continuity is disrupted and mechanical strength is reduced
Solution Approach 1:
The mechanical milling process is replaced with laser-based melting and deposition. The laser beam locally melts metal powders that are deposited to form the spiral rib, creating a continuous structure without cutting discontinuities. This thermal-additive approach preserves metal fiber continuity and enhances rib strength.
Solution Approach 2:
The process utilizes phase transitions of metal powders from solid to liquid (melting by laser beam) and back to solid (rapid cooling). This phase change mechanism allows the metal to be deposited and formed into a continuous rib structure without mechanical cutting, maintaining fiber continuity and structural integrity.
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 produces tools with improved mechanical strength and reduced wear, enabling longer tool life and lower production costs, while utilizing easily available market materials and simplifying the manufacturing process.
Implementation Method 1
a laser beam emitter (8) supplied by a laser source (9), through a fiber optic cable (10), which focuses, by means of optical devices with lenses and/or mirrors, the laser beam (11) on the peripheral surface (2C) of the tubular support body (2B)
Implementation Method 2
The coating by means of the laser cladding technique determines the formation of a surface layer with different composition than the base material
Implementation Method 3
Also usually advantageously provided is a supply of an inert gas, such as argon or nitrogen, at the emission nozzle of the head in order to prevent the oxidation of the powders during their rapid solidification
Data Source
Figure 1
Figure 2A~2G
Figure 3
AI summary
Method for making tools for machines adapted for forming threads on cylindrical bodies by means of plastic deformation, which provides for arranging a hollow tubular support body (2B) made of metal material facing the work head of an apparatus of laser cladding type and provided with a laser beam emitter and with a nozzle for emitting a flow of metal powders. The method provides for the controlled advancing of the work head along the longitudinal extension (Y) of the tubular support body (2B) for a plurality of longitudinal strokes and the controlled rotation of the tubular support body (2B) with respect to the work head for a plurality of rotations. There is then the controlled deposit of the coating bead (5) on the peripheral surface of the tubular support body (2B) and then the forming of a thread with excess material with respect to the profile of the thread to be made by means of the aforesaid controlled deposit of a plurality of adjacent beads during the combination of the controlled advancing of the work head and the controlled rotation of the tubular support body (2B). Finally, a step is provided for grinding the excess thread by means of removal of material which is outside the programmed profile of the thread.