Laser Resurfacing Welding for Cutting Roller Wear Resistance
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Solution Overview
Problem
Existing methods for producing cutting or embossing rollers in envelope or label production machines result in high production costs and reduced tool life due to wear and tear, with previous welding techniques like electrical wire welding causing undesirable weld splashes and cracks.
Innovation Solution
A method using laser resurfacing welding with a diode laser to apply powder material in single or multi-layers, controlling the laser power based on heat and light radiation emitted during the process to maintain constant temperature, ensuring uniform melting and homogeneity of the cutting or embossing projections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If electrical wire welding is used to apply cutting knives to the roller base body, then wear resistance is improved, but production time increases and weld quality deteriorates due to splashes, bubbles, and cracks
Solution Approach 1:
The patent replaces electrical wire welding with laser resurfacing welding, substituting a mechanical/electrical welding system with a laser-based thermal process. This substitution eliminates the need for wire feeding mechanisms and electrical contact, enabling faster processing without the harmful effects of traditional welding methods
Solution Approach 2:
The patent changes the welding parameters by using laser resurfacing welding instead of electrical wire welding. This parameter change includes using focused laser energy to melt and fuse powder material directly onto the roller surface, achieving high wear resistance with shorter processing time and without producing weld splashes, bubbles, or cracks
2Strength
If electrical wire welding is used to apply cutting knives to the roller base body, then wear resistance is improved, but weld quality deteriorates due to splashes, bubbles, and cracks
Solution Approach 1:
The patent replaces electrical wire welding with laser resurfacing welding, substituting a mechanical/electrical welding system with a laser-based thermal process. This substitution eliminates the need for wire feeding mechanisms and electrical contact, enabling faster processing without the harmful effects of traditional welding methods
Solution Approach 2:
The patent changes the welding parameters by using laser resurfacing welding instead of electrical wire welding. This parameter change includes using focused laser energy to melt and fuse powder material directly onto the roller surface, achieving high wear resistance with shorter processing time and without producing weld splashes, bubbles, or cracks
3Strength
If the entire cutting roller is milled from solid high-quality material, then cutting performance is improved, but production costs increase
Solution Approach 1:
The patent applies local quality by using laser resurfacing welding to apply high-alloy, wear-resistant powder material only to the cutting knife regions that require high performance, while the roller base body can be made from less expensive material. This localized application of high-quality material optimizes both performance and cost
Solution Approach 2:
The patent uses composite materials by combining a base body material with a high-alloy wear-resistant coating applied through laser resurfacing welding. The composite structure allows the roller to have both the mechanical properties of the base material and the wear resistance of the high-alloy coating, reducing overall production cost while maintaining cutting performance
4Manufacturing precision
If temperature control is implemented by measuring surface temperature after each layer, then homogeneity is improved, but production time increases due to time delays
Solution Approach 1:
The patent applies preliminary action by pre-calculating and storing reference temperature values that correspond to different process states. Instead of measuring temperature after each layer and waiting for cooling, the system proactively adjusts laser power based on pre-determined reference values, eliminating time delays while maintaining homogeneity
Solution Approach 2:
The patent implements feedback control by continuously monitoring the actual temperature of the workpiece and comparing it with stored reference temperature values. The laser power is automatically adjusted based on the difference between actual and reference temperatures, ensuring homogeneous material properties while maintaining high production speed through real-time control
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 production time and costs, enhances mechanical properties of the cutting or embossing projections by preventing cracks and anomalies, and allows for the production of novel metal alloys, improving wear resistance and tool life.
Implementation Method 1
a diode laser in particular is proposed for carrying out the laser resurfacing welding. This laser melts an additional material in powder form
Implementation Method 2
This laser melts an additional material in powder form, in order to thereby repair molding dies for injection molding and die-casting
Implementation Method 3
detection of the heat and/or light radiation emitted by the melt bath, at least during application of the layer
Implementation Method 4
detection of the heat and/or light radiation emitted by the melt bath
Implementation Method 5
control or regulation of the power of the laser being used for laser resurfacing welding, as a function of the heat and/or light radiation emitted by the melt bath, in such a manner that the temperature of the melt bath remains essentially constant
Data Source
AI summary
A method for producing a cutting or embossing roller having a cutting knife or embossing projection that projects out of the surface of a base body of the roller ensures the greatest possible optimal homogeneity of the cutting knife or the embossing projection, while minimizing production duration and costs. Single-layer or multi-layer application of the cutting knife or the embossing projection onto the roller base body occurs by laser resurfacing welding. Each layer is produced using an additional powdered material, which is melted in a melt bath at the weld point. The heat and/or light radiation emitted by the melt bath is detected, at least during application of each layer. Laser power is controlled or regulated as a function of the heat and/or light radiation emitted by the melt bath, so that melt bath temperature remains essentially constant during application of each layer.