Laser-Formed Cutting Blades Without Post-Grinding
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Solution Overview
Problem
The existing methods for forming cutting blades require grinding or sharpening of abrasive cutting material after deposition, which increases manufacturing time and complicates the processing due to the need for careful selection of winding materials to ensure proper adhesion of the cutting surface to the teeth.
Innovation Solution
A method using selective laser melting to form cutting blades by depositing layers of powder and fusing them with a laser beam, eliminating the need for grinding and allowing for the reuse of excess powder, while enabling customization of the cutting surface shape and material composition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If grinding or sharpening is used to form cutting surfaces on deposited abrasive material, then cutting performance is improved, but manufacturing time increases
Solution Approach 1:
The patent replaces the mechanical grinding or sharpening process with a laser-based selective melting process. The laser beam selectively melts and fuses abrasive particles to the tooth surfaces, directly forming the cutting surface without requiring subsequent mechanical grinding operations. This substitution eliminates the time-consuming grinding step while maintaining cutting surface quality.
Solution Approach 2:
The patent changes the processing parameters from mechanical removal (grinding) to thermal fusion (laser melting). By controlling laser power, scanning speed, and powder feed rate, the cutting surfaces are formed through controlled melting and solidification, achieving the desired surface quality in a single step without requiring post-processing grinding.
2Reliability
If winding materials are carefully selected to ensure proper adhesion of cutting surface to teeth, then adhesion quality is improved, but processing complexity increases
Solution Approach 1:
The patent replaces the winding material application process with direct laser melting of abrasive powder onto the tooth surfaces. The laser energy directly fuses the abrasive particles to the substrate through localized melting, eliminating the need for winding materials and the complex selection and application processes associated with them. This simplifies the processing while ensuring reliable adhesion through metallurgical bonding.
3Object-affected harmful factors
If excess powder is discarded after deposition, then contamination is reduced, but material waste increases
Solution Approach 1:
The patent implements a powder recovery system where excess powder that is not melted during the laser process is collected and retained for reuse. The system separates and recovers unused powder from the build area, allowing it to be reused in subsequent manufacturing cycles. This reduces material waste while maintaining contamination control through proper powder handling and filtration systems.
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 approach reduces manufacturing time, minimizes powder waste, and allows for the creation of customized cutting surfaces without the need for grinding, resulting in efficient and cost-effective production of cutting blades with enhanced cutting performance.
Implementation Method 1
scanning a laser beam over the deposited powder to fuse powder to the pre-formed teeth
Implementation Method 2
fuse powder to the pre-formed teeth
Data Source
AI summary
There is provided a method of forming cutting blades using selective laser melting comprising positioning a first part of an elongate strip (30) with pre-formed teeth (32) within a powder bed (20), forming coating layers layer-by-layer to create a cutting surface on each pre-formed tooth by repeatedly depositing a layer of powder on the powder bed and scanning a laser beam over the deposited powder to fuse powder to the pre-formed teeth.