Multi-Edge Weld Finishing Tool for One-Pass Allowance Removal
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Solution Overview
Problem
Conventional post-weld finishing methods like grinding lead to surface faults, residual stress, and increased fatigue, requiring manual labor, time, and protective measures, while being damaging to people and the environment.
Innovation Solution
A multi-edge cutting tool with linearly arranged teeth of varying heights, designed for one-pass removal of weld allowance, made from high-speed steel, allowing for efficient, accurate, and automated machining of complex surfaces with reduced labor intensity and environmental impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If grinding with an abrasive tool is used for post weld finishing, then the weld surface can be finished, but surface faults such as structural notches and residual stress are created leading to fatigue cracks and reduced reliability
Solution Approach 1:
The patent replaces the abrasive grinding mechanism with a mechanical cutting system using a disc-shaped tool with cutting edges. Instead of abrading the surface and creating notches, the cutting edges mechanically remove the weld reinforcement in a controlled manner, eliminating the creation of structural notches and residual stresses that lead to fatigue cracks.
Solution Approach 2:
The invention changes the fundamental parameter of the finishing process from abrasive removal to mechanical cutting. The disc-shaped tool with specifically designed cutting edges transforms the removal mechanism, allowing the weld face allowance to be removed cleanly without creating the harmful surface faults associated with grinding.
2Manufacturing precision
If manual grinding is used for post weld finishing, then the weld surface can be finished, but the process requires significant manual labor and time increasing the finishing duration
Solution Approach 1:
The patent replaces manual abrasive grinding with an automated mechanical cutting system. The disc-shaped tool with multiple cutting edges can be mounted on automated equipment, eliminating the need for manual operation while significantly reducing the time required to remove weld reinforcement from large surfaces.
Solution Approach 2:
The disc-shaped tool with its multiple cutting edges arranged radially can process various weld types and geometries, making it a universal solution that reduces the need for multiple specialized tools and operators, thereby decreasing overall finishing time.
3Manufacturing precision
If grinding with an abrasive tool is used for post weld finishing, then the weld surface can be finished, but the process is damaging to people and the environment requiring additional protective measures
Solution Approach 1:
The patent replaces the abrasive grinding process that generates harmful dust particles with a mechanical cutting system. The cutting edges remove material as chips rather than dust, significantly reducing environmental and health hazards and eliminating the need for extensive protective measures.
4Manufacturing precision
If traditional grinding equipment is used for post weld finishing, then the weld surface can be finished, but the process requires complex equipment with multiple components increasing device complexity
Solution Approach 1:
The patent segments the cutting function into multiple radial cutting edges on a single disc-shaped tool. This segmentation allows each cutting edge to handle a portion of the weld reinforcement removal, simplifying the overall equipment structure compared to traditional grinding systems while maintaining high processing efficiency.
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 tool ensures high machining accuracy, low surface roughness, and efficient processing of various weld surfaces, reducing labor and environmental impact, while enabling automation and prolonged tool life due to its design for variable loads and shock resistance.
Implementation Method 1
the weld face allowance is removed in one step in one pass of the cutting tool
Data Source
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Figure 3~4
AI summary
A method for finishing post-welding surfaces by moving the cutting tool along the weld; in this method the weld face allowance is removed in one step during a single pass of the cutting tool, which is equipped on one side with linearly arranged teeth, with the height of the cutting edge of successive teeth changing and increasing according to the direction of feed, and the difference in edge height between the first and last tooth being equal to the height of the cover pass allowance; the number of teeth is determined by the length of the weld, and the tooth length being at least half the distance between successive teeth. The subject of the invention is also a multi-edge tool for finishing welding surfaces, made in the form of a steel bar with a rectangular cross-section provided on one of the outer surfaces with tooth-shaped cutting elements, in which the width of tooth is equal to the maximum width of the allowance on the face, the length (g) of the tooth is at least half the distance (P) between teeth, and the difference in the height of the edges between the first tooth and the last tooth is equal to the height of the allowance that is to be removed, with the teeth arranged linearly and their number depending on the length of the welded joint.