Modular Cutting Tool Assembly With Standard Welding Precision
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Solution Overview
Problem
The existing methods for producing cutting tools with highly abrasive resistant materials, such as diamond-coated tools, are complex, costly, and inefficient for small-scale production due to the need for sophisticated laser welding and specialized equipment, limiting the number of workshops that can manufacture these tools and leading to high transportation costs and a lengthy logistics chain.
Innovation Solution
A cutting tool design that uses modular, sintered cutting members with an intermediate support member, allowing for standard welding techniques like MIG, MAG, or TIG welding, enabling decentralized assembly close to the point of use, reducing logistics and transportation costs by allowing assembly in local workshops without the need for laser welding equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If laser welding is used to attach sintered cutting members to the support body, then the cutting tool achieves high manufacturing precision and reliability, but the device complexity and production cost increase significantly
Solution Approach 1:
The patent introduces an intermediate layer between the sintered cutting member and the support body that simplifies the attachment process. This intermediate layer acts as a mediator that enables standard welding techniques to achieve reliable attachment without requiring complex laser welding equipment, thus reducing device complexity while maintaining attachment precision
Solution Approach 2:
The patent replaces the sophisticated laser welding system with standard welding techniques (MIG, MAG, or TIG welding). This substitution reduces the complexity of the installation while maintaining sufficient manufacturing precision for the cutting tool attachment
2Productivity
If laser welding equipment and specialized installation are used, then large quantities of identical parts can be assembled efficiently, but the production cost increases and adaptability to varying market needs decreases
Solution Approach 1:
The patent creates a universal attachment system using standard welding techniques that can be applied to various cutting tool configurations and market requirements. The simplified process allows the same installation methodology to serve multiple product types, enhancing adaptability while maintaining assembly efficiency
3Device complexity
If standard welding techniques are used to attach cutting members, then the device complexity and production cost are reduced, but the manufacturing precision and reliability of the attachment decrease
Solution Approach 1:
The intermediate layer serves as a mediator that enhances the reliability of standard welding techniques. It provides a suitable bonding surface that ensures strong and reliable attachment between the cutting member and support body, compensating for the lower inherent reliability of standard welding compared to laser welding
4Ease of operation
If complete cutting tools are transported to meet market demand, then the product availability is improved, but the weight of moving object and CO2 footprint increase
Solution Approach 1:
The patent segments the cutting tool into modular components: the support body can be transported separately from the sintered cutting members. This segmentation allows for lighter and more efficient transportation of individual components, reducing the weight of moving objects and CO2 footprint while maintaining product availability through local assembly
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 costs, minimizes the CO2 footprint by eliminating the need for transporting heavy tools, and allows for efficient assembly of cutting tools in various shapes and sizes using standard welding techniques, making it suitable for fluctuating market demands.
Implementation Method 1
The highly abrasive material is frequently grains or dust of diamonds, natural or synthetic, but other highly abrasive materials such as tungsten carbide may be used instead or in combination, e.g. sintered to form a cutting member.
Implementation Method 2
allowing for standard welding techniques like MIG, MAG, or TIG welding
Data Source
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AI summary
The invention relates to a method for producing and a cutting tool, respectively, for cutting hard materials such a natural stone or concrete or the like. A ductile support body (2) is the base body of the cutting tool, and a plurality of cutting modules (1) are arranged on the cutting edge of the cutting tool. The cutting member(10) is mounted on an intermediate support member (11), preferably by a laser weld (15),to form said cutting module (1). The modules (1) are attached to the support body (2) by means of a weld (14) in accurate manner, preferably by assistance of abutting support surfaces (120, 121, 123; 20, 21, 23) that hinder movement in at least 2 orthogonal directions, before welding each module (1) onto the support body (2). The invention enables production of pre-fabricated cutting modules (1) at central production sites, e.g. having expensive laser welding equipment, and shipment of these small pre-made modules (1) to distant locations where simple standard welding techniques may be used to produce a cutting tool.