Tip Dressing Cutter Rake-Groove Layout for Chip Load Relief

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Solution Overview

Problem

Existing tip dressing cutters for electrode tips in spot welding face issues with excessive load on rotary holders due to chip accumulation and lengthy lead times for cutter development, as recessed grooves are typically formed on the flank face after determining the electrode tip shape.

Innovation Solution

The tip dressing cutter features recessed grooves on the rake face instead of the flank face, with a serpentine cutting blade configuration that prevents chip accumulation between the cutting blade and the electrode tip, allowing for reduced load on the rotary holder and enabling pre-machining before determining the electrode tip shape.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If recessed grooves are formed on the flank face, then the cutter can remove material effectively, but chips accumulate in gaps between the recessed grooves and electrode tip causing large load on rotary holder

Engineering Contradiction:

Improvecutter designVSAvoidapparatus breakdown risk

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent inverts the conventional design by forming recessed grooves on the rake face instead of the flank face. This inversion changes the chip flow path so that chips are directed along the rake face away from the electrode tip, preventing accumulation in gaps and reducing load on the rotary holder.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent extracts the harmful function of chip accumulation from the cutting process by redesigning the groove location. The recessed grooves on the rake face serve to guide chips away from the critical gap area, effectively removing the problem of chip-induced loading.

Inventive Principle:

Principle #2Taking out (Extraction)

2Manufacturing precision

If recessed grooves are formed on the flank face after determining electrode tip shape, then the cutter matches the electrode tip geometry, but the development lead time increases

Engineering Contradiction:

Improvegrooved surface qualityVSAvoiddevelopment lead time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent enables preliminary machining of the recessed grooves on the rake face before the final electrode tip shape is determined. Since the rake face grooves can be formed independently of the specific electrode tip geometry, the cutter body can be prepared in advance, significantly reducing development lead time while still achieving precise grooved surfaces.

Inventive Principle:

Principle #10Preliminary action

3Productivity

If chips move into gaps between recessed grooves and electrode tip, then cutting action is maintained, but excessive load causes apparatus breakdown

Engineering Contradiction:

Improvecutting operation continuityVSAvoidapparatus durability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent converts the potentially harmful chip accumulation into a beneficial chip guidance system. The recessed grooves on the rake face actively direct chips away from the electrode tip gap, transforming what would be a harmful accumulation into a controlled chip flow path that protects the apparatus while maintaining cutting continuity.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Data Source

PatentUS11878357B2Tip dressing cutter

Publication Date: 2024.01.23 KYOKUTOH

AI summary

A cutter includes a rake face on which a recessed groove extending along a direction of a rotation axis of a rotary holder to be open at a flank face of the cutter are formed. The recessed groove includes a plurality of recessed grooves formed at predetermined intervals along a direction intersecting with the rotation axis. A cutting blade portion extending along a direction intersecting with the rotation axis is provided on a continuous portion of the rake face and the flank face. The cutting blade portion includes a first region made up of an intersecting portion of the rake face and the flank face and a second region made up of a peripheral edge portion of an opening portion of the recessed groove at the flank face.