'Zero radius' laser forming of tungsten carbide/superabrasive cutting edges and teeth

“我们将使用创新的增材制造技术，从根本上更新在锯片上形成硬齿的工艺。最常用的齿尖材料是碳化钨。在典型的尖端叶片中，使用的高值磨损材料不到1%。其余部分在制造过程中被机加工掉，或者留在底座上，当锋利的边缘磨损时丢弃。目前，最先进的碳化钨尖齿（TCT）是通过将预先成型的碳化钨镶块焊接到钢带上，然后将其磨成锋利的边缘而形成的。由于需要操作单个刀片，因此目前无法制造出细齿金属切削刀片（每英寸6齿）。研磨过程是环境浪费-材料，能源和冷却剂。我们的新工艺使用尖端材料的微激光金属沉积（micro- lmd）来形成硬切削刃，从而避免了操作和焊接TCT刀片的需要。在LMD中，一束粉末（如碳化钨）在被聚焦的激光束熔化到表面的同时被指向表面。我们已经获得了两项LMD制牙专利。与我们的分包商ManuDirect一起，我们在测试平台上对micro-LMD进行了实验，并能够在牙齿上实现坚硬表面，并证明了它们的切割能力。这些牙齿的边缘仍然是圆的；我们还不能形成一个锋利的“零半径”切削刃。然而，一旦我们能够这样做，我们将创造一个近净形状的牙齿，减少或消除后续研磨的需要，甚至允许激光锐化。我们的工艺也应该适用于所有类型的叶片和其他金属陶瓷组合。然而，由于碳化钨是应用最广泛的磨料，它是我们最初关注的重点。最大的机会将是在细齿金属切削刀片（\ bbb6 TPI），目前不可能使用TCT刀片，传统的双金属刀片容易钝化。此外，我们看到了在成本和性能方面介于双金属和TCT之间的木材切割锯片的机会。主要合作伙伴是磨料锯片的制造商和出口商，并将通过其客户群开发该过程。该联盟包括一家粉末供应商、英国该领域的顶尖大学和一家微型lmd设备专家分包商。”

"We will use innovative additive manufacturing to radically update the process for forming hard teeth on saw blades. The most commonly used tooth tip material is tungsten carbide. In a typical tipped blade less than 1% of the high value wear material is used. The rest is machined off during the manufacturing process or left on the base and discarded when the sharp edges are worn.State-of-the-art tungsten carbide tipped (TCT) teeth are currently formed by welding pre-formed tungsten carbide inserts to steel strip and then grinding these to a sharp edge. The need to manipulate individual inserts means that fine-toothed metal-cutting blades ( \>6 Teeth Per Inch) cannot currently be manufactured. The grinding process is environmentally wasteful - of materials, energy and coolant.Our new process uses micro laser metal deposition (micro-LMD) of the tip material to form the hard cutting edge, thus avoiding the need to manipulate and weld TCT inserts. In LMD, a jet of powder (eg tungsten carbide) is directed at a surface while being simultaneously melted into the surface by a focused laser beam. We have obtained two patents on tooth-making via LMD. With our subcontractor ManuDirect we have experimented with micro-LMD in a test rig and have been able to achieve hard surfaces on teeth and proved their ability to cut.The edges of these teeth are still rounded; we are not yet able to form a sharp 'zero radius' cutting edge. However, once we are able to do so, we will have created a near-net-shape tooth, reducing or eliminating the need for subsequent grinding, or even permitting laser sharpening.Our process should also be applicable to all types of blade and other metal-ceramic combination. However as tungsten carbide is the most widely used abrasive it is our initial focus. The greatest opportunity will be in fine-toothed metal-cutting blades ( \>6 TPI) where there is currently no possibility of using TCT inserts and conventional bimetal blades blunt easily. In addition, we see an opportunity for a wood cutting saw blade that sits in the gap between bimetal and TCT in terms of cost and performance.The lead partner is a manufacturer and exporter of abrasive saw blades and will exploit the process through its customer base. The consortium includes a powder supplier, the UK's leading university in this area and a subcontractor that is expert in micro-LMD equipment."