Saw Blade Welded Inserts with Relocated Chip Breakers
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Solution Overview
Problem
Existing saw blades with soldered inserts require large, expensive carbide inserts for sufficient holding forces, limiting the pitch distance between teeth and increasing material consumption, while also complicating the geometry and grinding process.
Innovation Solution
The use of welded inserts with chip breakers relocated to the projection, allowing for smaller inserts and reduced material usage, enabling smaller pitches and improved surface quality with reduced grinding requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If large-volume inserts are used with soldering, then sufficient holding forces are achieved, but material consumption increases and pitch distance is limited
Solution Approach 1:
The patent changes the joining method from soldering to welding, which fundamentally alters the connection strength parameters. Welding provides higher holding forces per unit area compared to soldering, allowing smaller inserts to achieve the same holding force. This parameter change resolves the contradiction by enabling reduced material consumption while maintaining sufficient holding strength.
Solution Approach 2:
The patent employs composite material strategy by combining the base body material with hard metal inserts through welding. The welding process creates a metallurgical bond that integrates the insert with the base body, forming a composite structure with optimized properties. This allows using smaller amounts of expensive hard metal material while achieving superior holding forces compared to soldered joints.
2Strength
If large joining surface is used for soldering, then sufficient holding forces are achieved, but insert size increases and pitch is limited
Solution Approach 1:
The patent fundamentally changes the joining parameter from soldering to welding. Welding creates stronger bonds per unit area, allowing the joining surface to be significantly reduced. This enables using smaller inserts with less volume while achieving equal or superior holding forces, directly resolving the contradiction between holding force and insert volume.
Solution Approach 2:
The patent extracts the chip breaker function from the insert and relocates it to the base body. This extraction reduces the required insert volume since the insert no longer needs to accommodate chip breaker geometry. The holding force requirement is simultaneously addressed by using welding instead of soldering, allowing smaller inserts to suffice.
3Ease of operation
If complex insert geometry is used for chip breakers, then chip formation is improved, but manufacturing complexity and grinding requirements increase
Solution Approach 1:
The patent segments the tooth structure into two separate components: the insert containing only the cutting edge, and the base body containing the chip breaker. This segmentation allows each component to be optimized independently. The insert geometry is simplified to reduce manufacturing complexity, while the chip breaker function is maintained on the base body, resolving the contradiction between ease of operation and device complexity.
Solution Approach 2:
The patent extracts the chip breaker feature from the insert and relocates it to the base body. This extraction eliminates the need for complex insert geometry required to accommodate chip breakers. The insert can now be manufactured with simpler geometry, reducing grinding requirements and manufacturing complexity, while chip formation functionality is preserved on the base body.
4Quantity of substance
If smaller inserts are used to reduce material costs, then material consumption decreases, but holding forces become insufficient with soldering
Solution Approach 1:
The patent changes the joining method parameter from soldering to welding, which increases the strength per unit area of the joint. This parameter change allows using smaller inserts with reduced material consumption while maintaining or improving holding forces. The welding process provides sufficient holding strength even with minimized insert sizes.
5Manufacturing precision
If pitch distance is reduced to improve surface quality, then surface quality improves, but joining area becomes too small for soldering
Solution Approach 1:
The patent changes the joining method from soldering to welding, which allows sufficient holding forces with smaller joining areas. This enables reducing the pitch distance between teeth while maintaining adequate joining area for the welding process. Smaller pitch distances improve surface quality by creating finer cutting patterns, and welding makes this possible without compromising joint strength.
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 solution enhances holding forces, reduces material costs, and allows for smaller pitches and improved surface quality by using welded connections and relocating chip breakers, while also improving temperature resistance and minimizing heat input to the base body.
Implementation Method 1
The insert (4) is connected to the projection (3) by a welding process, in particular by resistance welding
Implementation Method 2
resistance welding
Data Source
Figure 1~7
AI summary
The blade (1) has chip formation surface (7) welded at the joining area (5) with the projection (3) at the base (2). The projection has a laminar chip breaker (8) at the base. The projection is turned to chip formation surface arranged at the element (4) of the chip breaker turning into the projection of the base. The blade has smaller even divisions.