Weld Bead Cutting with Variable Feed for Continuous Chip Recovery
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Solution Overview
Problem
The existing weld bead cutting methods face challenges in efficiently cutting weld beads on the outer circumference of welded resin members, particularly due to variations in weld bead width and end edge positions, which can result in high rigidity cutting chips that are difficult to recover, leading to prolonged machining times and incomplete removal.
Innovation Solution
A weld bead cutting device and method that incorporates a bead end edge position measuring device, bead profile information creation, machining information creation, and cutting tool feed control to adjust the cutting tool's position and feed pitch, ensuring the cutting chip has a predetermined sectional shape and is continuous, facilitating easy recovery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the cutting tool is moved at a fixed feed pitch to cut the weld bead, then the machining process is simple, but the cutting chip becomes discontinuous and difficult to recover when weld bead width varies
Solution Approach 1:
The patent applies dynamics by making the feed pitch variable rather than fixed. The feed pitch is adjusted dynamically based on the measured width of the weld bead at each position, allowing the cutting tool to maintain continuous contact with the weld bead and generate continuous cutting chips that are easy to recover, while adapting to variations in weld bead dimensions.
Solution Approach 2:
The patent implements feedback by measuring the weld bead width at each position and using this measurement to determine the appropriate feed pitch for the next cutting step. This closed-loop control ensures that the cutting parameters are continuously optimized based on actual weld bead conditions, maintaining chip continuity and recoverability.
2Productivity
If the feed pitch is reduced to ensure continuous cutting chip generation, then cutting chip recovery is improved, but the machining time increases
Solution Approach 1:
The patent changes the feed pitch parameter dynamically based on weld bead width measurements. Instead of using a conservatively small fixed feed pitch that would ensure chip continuity but increase machining time, the system adjusts the feed pitch to match actual weld bead dimensions, optimizing the balance between chip continuity and machining efficiency.
3Productivity
If the cutting tool position is not adjusted according to weld bead width variations, then the machining process is fast, but incomplete weld bead removal occurs
Solution Approach 1:
The patent applies preliminary action by measuring the weld bead width at each position before cutting and pre-calculating the appropriate feed pitch. This allows the cutting tool to be positioned and parameterized optimally before each cutting pass, ensuring complete weld bead removal without requiring multiple trial passes or slow manual adjustments.
Data Source
AI summary
Positions of both end edges of a weld bead in a bead width direction are measured over the entire circumference of a liner in a circumferential direction of the liner. Based on information on the position of the end edge, bead profile information being information on a shape of the end edge of the weld bead over the entire circumference of the liner in the circumferential direction is created. Based on this bead profile information, machining information of the liner per rotation of the liner being position information of a cutting tool in the bead width direction per phase in the circumferential direction of the liner is created so that a moving locus of the cutting tool relative to the liner along the circumferential direction of the liner approximates the shape of the end edge of the weld bead over the entire circumference of the liner in the circumferential direction.