Weld Bead Removal Using a High-Melting-Point Scraper
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for removing weld beads are inefficient, as they require waiting for the beads to solidify, leading to prolonged cycle times and adhesion issues with cutting tools, and involve scattering of chips during removal, making recovery difficult.
Innovation Solution
A method using a scraper with a melting point higher than the base material and welding rod, which creates a molten pool and separates elevated bead portions while molten, discharging them rearward to avoid scattering and adhesion, and includes a recovery unit for efficient material collection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a rotary cutting tool is used to remove solidified beads, then the beads can be removed from the base material, but chips scatter all around making recovery troublesome
Solution Approach 1:
The invention extracts the harmful scattering function from the cutting process by using a scraper that contains and directs chips in a controlled manner. The scraper design with specific angles and a chip collection groove allows beads to be removed while chips are contained and directed rearward, preventing scattered distribution around the work area.
Solution Approach 2:
The scraper acts as an intermediary tool between the bead removal process and chip collection. By using a non-rotating scraper with a controlled chip flow path, the system mediates between the need for effective bead removal and the need for clean chip recovery, eliminating the scattering problem inherent in rotary cutting tools.
2Manufacturing precision
If a rotary cutting tool is used for bead removal, then beads can be removed, but driving equipment is required and adhesion suppression operations are needed
Solution Approach 1:
The invention replaces the complex rotary cutting tool system with a simpler non-rotating scraper. The scraper uses direct mechanical contact with specific geometric angles to remove beads, eliminating the need for motors, bearings, and coolant systems required by rotary tools. The scraper is simply moved linearly across the bead to achieve removal.
Solution Approach 2:
The scraper is designed as a simple, inexpensive tool that can be easily replaced if needed, unlike expensive rotary cutting tools with complex drive mechanisms. The scraper's simple geometry and lack of moving parts make it a cost-effective, maintenance-free solution for bead removal.
3Reliability
If bead removal is performed after solidification, then the beads are stable for removal, but the product cycle time is prolonged
Solution Approach 1:
The invention changes the temperature parameter from cold (solidified state) to hot (molten state) for bead removal. By performing removal while beads are still molten, the process eliminates the waiting time for solidification. The scraper is designed with materials and geometries suitable for high-temperature operation, enabling effective removal in the molten state without compromising reliability.
Solution Approach 2:
The invention performs bead removal as a preliminary action immediately after welding while the beads are still hot and pliable, rather than waiting for complete solidification. This timing optimization reduces cycle time by eliminating the idle waiting period, and the scraper design ensures reliable removal even in this transitional thermal state.
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 shortens cycle time, prevents adhesion, and facilitates easy recovery of weld beads without scattering, allowing for efficient removal and collection at a lower temperature.
Implementation Method 1
preparing a scraper made of a material with a melting point that is higher than a melting point of a base material that is an object of welding and a melting point of a welding rod
Implementation Method 2
creating a molten pool in which the base material and the welding rod are fused together, by heating the base material and the welding rod at a temperature lower than the melting point of the scraper
Implementation Method 3
separating at least a portion of material making up an elevated portion by the scraper, by moving the scraper to the elevated portion of the bead that is raised from the molten pool above a surface of the base material while the molten pool is molten
Implementation Method 4
discharging the at least a portion of the material rearward, in a direction opposite to forward that is a direction of movement of the scraper in the step (c), by causing the at least a portion of the material to move along a second face of the scraper on a side opposite to a first face facing the base material
Data Source
AI summary
The method for removing a weld bead includes (a) the steps of preparing a scraper having a higher melting point than the melting points of the base metal and the welding rod; (b) heating the base metal and the welding rod to a temperature lower than the melting points of the scrapers to form a molten pool in which the base metal and the welding rod are fused together; (d) moving the at least part along a second surface of the scraper opposite to the first surface facing the base material, thereby discharging the at least part backward, opposite to the forward movement direction of the scraper in step (c).