Load Beam Surface Finishing via Laser Modified Layer
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Solution Overview
Problem
Existing methods for finishing the surface of three-dimensional objects like dimples in disk drives indirectly improve surface accuracy, which is not sufficient for precise smooth movement of sliders, and require complex laser beam distance control for uniform modification.
Innovation Solution
A method involving laser irradiation of a flat plate work to form a modified layer, followed by plastic working such as cold forging and pressing, directly improves the surface finishing accuracy of functional parts like dimples and tabs on a load beam without the need for complex distance control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If water jet and fine particles are used to finish the concave surface of the dimple die, then the surface is finished into a mirror surface, but the dimple die must be movably supported and the process is complex
Solution Approach 1:
The patent replaces the mechanical water jet and particle feeding system with a laser beam system to finish the concave surface of the dimple die. The laser beam directly irradiates the surface to achieve mirror finishing without requiring complex mechanical support structures or particle feeding mechanisms, thus resolving the contradiction between manufacturing precision and device complexity.
Solution Approach 2:
The patent changes the physical state of the dimple die surface by using laser irradiation to melt and resolidify the surface layer, transforming it into a mirror surface. This parameter change approach achieves high surface finishing accuracy without the need for complex mechanical processing systems.
2Manufacturing precision
If laser beam is used to directly improve surface finishing accuracy of the functional part, then the surface roughness is reduced uniformly, but the laser beam distance control becomes complex
Solution Approach 1:
The patent performs preliminary action by irradiating the flat plate work with laser beam before plastic working to form the functional part. This creates a modified layer on the surface that will be subsequently formed into the three-dimensional functional part, ensuring uniform surface finishing accuracy is built into the structure from the beginning rather than requiring complex distance control during three-dimensional forming.
Solution Approach 2:
The patent inverts the conventional approach by first creating the modified layer on the flat plate and then forming the three-dimensional functional part from it, rather than forming the three-dimensional part first and then finishing its surface. This inversion eliminates the need for complex laser beam distance control during the forming process.
3Ease of operation
If the concave surface of the dimple die is finished indirectly, then the dimple surface becomes smooth, but the surface finishing accuracy is not sufficient for precise slider movement
Solution Approach 1:
The patent applies preliminary laser irradiation to create a uniformly smooth modified layer on the flat plate before forming the dimple. This preliminary action ensures that when the dimple is formed, its surface inherits the uniform smoothness directly, achieving both ease of operation for slider movement and high manufacturing precision.
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 results in uniformly smooth surfaces with reduced surface roughness, enhancing the functional performance of dimples and tabs in load beams, ensuring smooth slider movement and improved load/unload operations.
Implementation Method 1
irradiating the surface of a part of the work where a functional part is formed with a laser beam, to form a modified layer in the irradiated part
Implementation Method 2
the modified layer is formed by melting and softening the part of the surface of the work with a laser beam
Data Source
AI summary
A method of manufacturing a load beam directly improves the finishing accuracy of the surface of the load beam having a tab and/or a dimple, and the method includes a modifying process of preparing a flat plate work serving as the load beam and irradiating a part of a surface of the work where the tab and/or the dimple is formed with a laser beam, to form a modified layer in the irradiated part and a forming process of carrying out plastic working on the part where the modifies layer is present, to form the tab and/or the dimple in the part where the modified layer is present.