US20060032333A1 - Solid state processing of industrial blades, edges and cutting elements - Google Patents
Solid state processing of industrial blades, edges and cutting elements Download PDFInfo
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- US20060032333A1 US20060032333A1 US11/090,317 US9031705A US2006032333A1 US 20060032333 A1 US20060032333 A1 US 20060032333A1 US 9031705 A US9031705 A US 9031705A US 2006032333 A1 US2006032333 A1 US 2006032333A1
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Images
Classifications
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
- C21D9/18—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for knives, scythes, scissors, or like hand cutting tools
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23D—PLANING; SLOTTING; SHEARING; BROACHING; SAWING; FILING; SCRAPING; LIKE OPERATIONS FOR WORKING METAL BY REMOVING MATERIAL, NOT OTHERWISE PROVIDED FOR
- B23D63/00—Dressing the tools of sawing machines or sawing devices for use in cutting any kind of material, e.g. in the manufacture of sawing tools
- B23D63/08—Sharpening the cutting edges of saw teeth
- B23D63/12—Sharpening the cutting edges of saw teeth by grinding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
- B23K20/12—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding
- B23K20/122—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding using a non-consumable tool, e.g. friction stir welding
- B23K20/1225—Particular aspects of welding with a non-consumable tool
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
- B23K20/12—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding
- B23K20/122—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding using a non-consumable tool, e.g. friction stir welding
- B23K20/1275—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding using a non-consumable tool, e.g. friction stir welding involving metallurgical change
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
- B23P15/28—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass cutting tools
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
- B23P15/28—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass cutting tools
- B23P15/40—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass cutting tools shearing tools
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
- C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C26/00—Coating not provided for in groups C23C2/00 - C23C24/00
Definitions
- This invention relates generally to industrial blades. More specifically, the invention relates to a method for improving characteristics of industrial blades, edges and cutting elements.
- Sharpness and the ability to retain a sharp edge are just two important criteria for an industrial blade. It is often the case that industrial blades are smaller components of much larger systems. Other industrial blades are cutters, borers, milling blades, drill bits, openers, groovers, crushers, reamers, saw blades and knives of various sorts that are used to perform various industrial applications in many different industries. Regardless of the industry, an industrial blade that can remain sharp and resist chipping for longer periods of time results in substantial time and cost benefits.
- impact resistance and toughness is inversely related to wear resistance and hardness for most industrial blade materials. Therefore, different industrial blades are typically required for impact applications and sharpness applications.
- Certain industrial blades have been specifically designed to withstand the impact of cutting hard material without the edge chipping.
- increased impact toughness means lower RC hardness as compared to the higher RC values of other industrial blades.
- edge retention the ability to maintain a sharp edge (referred to hereinafter as edge retention) is compromised.
- a technique has been developed to test several different types of steel at different “Rockwell” or RC hardness measurements until a happy medium is found between “good” edge retention, where there is no dulling of the industrial blade, and the prevention of edge chipping.
- a conventional D2 steel hand-held cleaver such as a Brown BearTM Cleaver
- a rope is repeatedly cut with the hand-held cleaver
- the edge retention is typically not up to par with harder hand-held knife blades, such as a JaegerTM Boning knife also sold by Knives of Alaska.
- harder hand-held knife blades that offer increased edge retention in low impact cutting applications typically experience edge chipping when used to cut or chop through harder material such as hard wood and bone due to the increased brittleness of the hand-held blade.
- an industrial blade like a hand-held blade, would be able to withstand abrasive cutting and retain a sharp edge, yet be able to withstand the high impact necessary to chop through hard materials without the edge chipping or fracturing.
- the present invention provides a method for enhancing the mechanical properties of an industrial blade.
- the present invention provides an industrial blade having superior edge retention and a method for forming the same.
- the invention provides a method for forming a cutting edge on an industrial blade that will result in superior resistance to chipping.
- the present invention provides a system and method for friction stir processing of an industrial blade, wherein friction stir processing techniques are used to modify the properties of the industrial blade to thereby obtain superior edge retention and superior resistance to chipping.
- FIG. 1 is a perspective view of one tool that can be used to perform the friction stir processing of the present invention.
- FIG. 2 is a cross-sectional view of another tool that can be used to perform the friction stir processing of the present invention.
- FIG. 3 is a cross-sectional view of another tool that can be used to perform the friction stir processing of the present invention.
- FIG. 4 is a cross-sectional view of a material that is friction stir processed to modify the characteristics of the material.
- FIG. 5 is a cross-sectional view of a material that is friction stir processed to modify the characteristics of the material, and having an overlay identifying where a cutting edge could be formed from the friction stir processed material.
- FIG. 6 is a cross-sectional view of material that has been friction stir mixed so as to include another material.
- FIG. 7 is a cross-sectional view of one embodiment for friction stir mixing an additive material 112 into another using a mesh or screen 110 to hold the additive material 112 in place.
- FIGS. 8-66 are various industrial blades.
- the present invention provides a system and method for performing friction stir processing on an industrial blade.
- the friction stir processing can be performed in one embodiment on a surface of a workpiece that is fashioned into the industrial blade.
- the friction stir processing can be performed deeper into the workpiece.
- FIG. 1 is a perspective view of a tool being used for friction stir welding that is characterized by a generally cylindrical tool 10 having a shoulder 12 and a pin 14 extending outward from the shoulder.
- the pin 14 is rotated against a workpiece 16 until sufficient heat is generated, at which point the pin of the tool is plunged into the plasticized workpiece material.
- the workpiece 16 is often two sheets or plates of material that are butted together at a joint line 18 .
- the pin 14 is plunged into the workpiece 16 at the joint line 18 .
- FIG. 2 is a cross-sectional view of a cylindrical friction stir processing tool 20 .
- the friction stir processing tool 20 has a shank 22 and a shoulder 24 , but no pin. Therefore, instead of plunging a pin into the material to be solid state processed, the shoulder is pressed against the material. Penetration by the shoulder is typically going to be restricted to the surface of the material or just below it because of the larger surface area of the shoulder as compared to the pin.
- the pin 16 of the tool 10 in FIG. 1 does not have to be plunged into the material, the pin is more likely to be designed for easy penetration.
- the pin 16 is more likely to have a very small surface area as compared to the tool 20 of FIG. 2 , the pin is more likely to plunge into the material.
- FIG. 3 is provided as an alternative embodiment for a tool having no pin.
- FIG. 3 shows a tool 30 having a shank 32 that is smaller in diameter than the shoulder 34 . This design can be more economical because of less material used in its construction, depending upon the diameter of the shoulder 34 .
- nucleation observations indicate that there may be more nucleation sites in the processed material due to the energy induced into the material from friction stir processing. Accordingly, more of the solute material may be able to come out of solution or precipitate to form higher densities of precipitates or second phases.
- FIG. 4 a section of ATS 34 steel was friction stir processed by plunging a tool similar to the tool shown in FIG. 2 into the workpiece 70 and moving the tool transversely along a middle length thereof. Transverse movement would be perpendicular to the page, thus FIG. 5 is a cross-sectional view of the base material 70 .
- FIG. 4 shows that the tool plunged into the base material 70 from the top 72 .
- the stir zone 74 is shown having a hardness of 60 RC.
- the base material 70 is shown as having a hardness value of 44 RC at a location 76 .
- an unprocessed or original base material zone is shown as having retained, in other samples, its original hardness value of 12 RC at approximately location 78 .
- FIG. 5 is an illustration of an overlay 90 of a cutting edge on the ATS-34 steel base material 70 .
- the overlay 90 indicates one advantageous configuration of an industrial blade that could be machined from the material 70 , wherein the configuration takes the greatest advantage of the improved toughness and hardness characteristics of the friction stir processed material 70 .
- the industrial blade overlay 90 is formed in the processed region 74 that will result in a hard and yet tough cutting edge.
- any object being formed from a processed material can be arranged to provide the most advantageous properties where it is most critical for the object. In this example, a beneficial cutting edge will be achieved from having an edge disposed well within the processed material.
- three hand-held blades processed using a friction stir processing system and method in accordance with the present invention were prepared and tested against conventional blades.
- the creation of the test blades was accomplished by friction stir processing a workpiece that was then finished to form a hand-held knife blade having a profile substantially identical to a conventional knife blade used for a comparison.
- the hand-held test blades of the present invention were created by machining the hand-held test blades in accordance with the following instructions.
- the first attempt at grinding was to obtain a 22 degree angle with a 600 grit diamond belt. The result was a polished edge.
- a 320 diamond grit was then used with good results to further refine the hand-held blade.
- the desired angle was established and after a few passes, the cutting edge was placed against the 600 grit diamond belt to establish the desired wire “burr”.
- the wire burr was removed with an 8,000 grit diamond belt and then polished with a 50,000 grit diamond belt.
- a razor “shaving” edge was established on the test blades and the cutting edge appeared to remain totally within the processed material.
- friction stir mixing provides for additional additive materials to be included in the friction stir mixing process.
- the additive materials become an integral part of the resulting industrial blades.
- FIG. 6 is a cross-sectional view of a base material that has been friction stir mixed so as to include another additive material. Specifically, a steel member 100 has been friction stir mixed so as to work in diamond particles 102 into the steel member.
- FIG. 7 is a cross-sectional view of one embodiment for friction stir mixing an additive material 112 into another using a mesh or screen 110 to hold the additive material 112 in place.
- a stainless steel mesh or screen 110 is being used to hold carbide 112 in the form of a powder.
- the screen 110 and carbide powder 112 are disposed on the surface of a base material 114 .
- the surface of the base material 114 is then friction stir processed, resulting in a mixing of the stainless steel 110 , the carbide 112 , and the base material 114 at the surface of the base material.
- the different materials could be mixed further into the base material 114 using a tool having a pin, or by using a tool having a shoulder that is pressed harder into the base material.
- An important concept of the present invention is that solid state processing or friction stir processing that is performed is a temporary transformation into a plasticized state.
- the material that is used as the workpiece and formed into the industrial blade may not pass through a liquid state.
- a first chopping test was performed on a green red oak limb; a second chopping test was performed on a dried Osage orange limb, which is an extremely hard, dense wood; a third chopping test was performed on an elk antler (bone); a fourth chopping test was performed on a brick block, and a fifth chopping test was performed on a steel anvil.
- Results for chopping with the test blade are as follows in Table 1: TABLE 1 Test Result Green red oak No edge chipping; edge will still shave dry hair Dried Osage No edge chipping; edge will still Orange shave dry hair Elk antler No edge chipping; minor edge wear evident; would shave wet hair Brick Edge damage evident with several small chips and dulled edge Steel anvil Small edge separation at point of machining groove for friction stir
- Both hand-held cleavers were able to consistently cut through bone and hard wood without chipping.
- the hand-held test blade was found to provide greater edge retention over the conventional hand-held cleaver.
- a second hand-held test blade was sharpened to perform new tests.
- the second test blade was used to cut rope for 30 minutes. In that time, 607 cuts were made until the rope was gone.
- the second hand-held test blade still shaved dry hair afterwards.
- hand-held test blades Further tests were performed on hand-held test blades, such as the sharpness test of the friction stir processed edge.
- five different Knives of AlaskaTM, Inc. hand-held knife models were first tested. These hand-held knives include the Alaskan Brown Bear Skinner/Cleaver (D2 steel; RC 55-57), the Jaeger Boning Knife (ATS-34 steel; RC 59-61), the Bush Camp Knife (AUS8 steel; RC 57-59), the Coho fisherman's knife (hollow ground AUS8 steel; RC 57-59), and the Magnum Ulu (D2 steel; RC 59-61). The final test was on a hand-held test blade with the friction stir processed edge.
- the test for sharpness involved placing a 3 ⁇ 4 inch thick hemp rope on a 2 ⁇ 6 board. A section on each knife was selected and the rope was cut completely through by striking the back of the blade with a soft mallet. The rope was repeatedly cut, at the same point on the hand-held knife blade. The number of cuts was recorded for each hand-held blade. When the hand-held knife's tested section would no longer shave dry hair on the tester's arm—this was recorded as one past the maximum number of cuts that that hand-held blade steel would retain a shaving edge.
- Test results are as follows as shown in Table 2: TABLE 2 Number of Cuts Where hand-held Hand-held Knife Knife No Longer Shaves Alaskan Brown Bear 17 Jaeger Boning Knife 67 Bush Camp Knife 41 Coho Fisherman's Knife 14 Magnum Ulu 52 Test Blade 100+
- test blades formed in accordance with the present invention held up to and exceeded expectations in the sharpness category and in the impact test results. Conventionally, it is unexpected to be able to take a two pound hand-held test blade and swing it smartly to cut through a hard material such as elk antler, repeatedly, and still retain a shaving edge with no edge fracturing. Such performance is unheard of in the hand-held knife industry.
- Friction stir processing may be applied to any hand-held knife blade to enhance performance characteristics of the blades.
- hand-held knife blades may be formed of any material known in the art, including D2 steel, ATS-34 steel, AUS8 steel, S-30V steel, or other materials.
- FIGS. 8-66 are provided as illustrations of the many different types of industrial blades that are considered to be within the scope of the embodiments of the present invention. However, the following list of industrial blades should not be considered limiting, as there are other industrial blades that can also take advantage of the benefits of the embodiments of the present invention.
- FIGS. 8-66 includes the following industrial blades: angle milling cutter, boring tools, broach, burr, chanfer cutter, circular cutting blades for food, metal or paper, converting slitters, counter bores, counter sinks, cutting tool endmill, cutting tool reamer, deburring tool, drill bit, endmill, fishing milling cutter, food processing, form cutter, gear cutting tool, gear shaper tool-shaving cutter, grooving tool, guillotine paper and food cutting blades, gun drill and reamers, helical end mill, hobs, hobs and side milling cutters, hole opener, hole saw, hydraulic pipe cutter, jaw crusher, keyseat cutter, metal working shear blades, milling cutter, packaging and cutoff knives, plastic granulating knives, press brake dies, reamer, rotaryfile cutter, round textile knife, router bit, saw blades, shear blades, shell end mills, side milling cutter, slitter blades for packaging, tap cutter, taps, textile knives, thin disk cutters,
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Abstract
Description
- This document claims priority to and incorporates by reference all of the subject matter included in the provisional patent applications having docket number 2992.SMII.PR with Ser. No. 60/556,050 and filed Mar. 24, 2004, docket number 3043.SMII.PR with Ser. No. 60/573,707 and filed May 21, 2004, docket number 3208.SMII.PR with Ser. No. 60/637,223 and filed Dec. 17, 2004, and docket number 3212.SMII.PR with Ser. No. 60/654,608 and filed Feb. 18, 2005.
- 1. Field of the Invention
- This invention relates generally to industrial blades. More specifically, the invention relates to a method for improving characteristics of industrial blades, edges and cutting elements.
- 2. Description of Related Art
- It should be understood that the present invention applies to any type of industrial blade, edge, or cutting elements where sharpness, the ability to remain sharp, and resistance to chipping are important features. Hereinafter, the terms “edge” and “cutting element” are to be considered included in the term “industrial blade.”
- Sharpness and the ability to retain a sharp edge are just two important criteria for an industrial blade. It is often the case that industrial blades are smaller components of much larger systems. Other industrial blades are cutters, borers, milling blades, drill bits, openers, groovers, crushers, reamers, saw blades and knives of various sorts that are used to perform various industrial applications in many different industries. Regardless of the industry, an industrial blade that can remain sharp and resist chipping for longer periods of time results in substantial time and cost benefits.
- It is noted that impact resistance and toughness is inversely related to wear resistance and hardness for most industrial blade materials. Therefore, different industrial blades are typically required for impact applications and sharpness applications.
- Certain industrial blades have been specifically designed to withstand the impact of cutting hard material without the edge chipping. Generally, increased impact toughness means lower RC hardness as compared to the higher RC values of other industrial blades. As a result, the ability to maintain a sharp edge (referred to hereinafter as edge retention) is compromised. A technique has been developed to test several different types of steel at different “Rockwell” or RC hardness measurements until a happy medium is found between “good” edge retention, where there is no dulling of the industrial blade, and the prevention of edge chipping.
- When examining industrial blades, it is useful to examine analogous blades in the hand-held blade industry. For example, a conventional D2 steel hand-held cleaver, such as a Brown Bear™ Cleaver, is designed to consistently cut through bone without chipping. However, when a rope is repeatedly cut with the hand-held cleaver, the edge retention is typically not up to par with harder hand-held knife blades, such as a Jaeger™ Boning knife also sold by Knives of Alaska. Similarly, harder hand-held knife blades that offer increased edge retention in low impact cutting applications typically experience edge chipping when used to cut or chop through harder material such as hard wood and bone due to the increased brittleness of the hand-held blade.
- Ideally, an industrial blade, like a hand-held blade, would be able to withstand abrasive cutting and retain a sharp edge, yet be able to withstand the high impact necessary to chop through hard materials without the edge chipping or fracturing.
- Accordingly, what is desired is an industrial blade that can withstand the high impact of chopping or cutting through hard materials, and still provide superior edge retention.
- In one aspect, the present invention provides a method for enhancing the mechanical properties of an industrial blade.
- In another aspect the present invention provides an industrial blade having superior edge retention and a method for forming the same.
- In another aspect, the invention provides a method for forming a cutting edge on an industrial blade that will result in superior resistance to chipping.
- In one embodiment, the present invention provides a system and method for friction stir processing of an industrial blade, wherein friction stir processing techniques are used to modify the properties of the industrial blade to thereby obtain superior edge retention and superior resistance to chipping.
- These and other aspects, features, advantages of the embodiments of the present invention will become apparent to those skilled in the art from a consideration of the following detailed description taken in combination with the accompanying drawings.
-
FIG. 1 is a perspective view of one tool that can be used to perform the friction stir processing of the present invention. -
FIG. 2 is a cross-sectional view of another tool that can be used to perform the friction stir processing of the present invention. -
FIG. 3 is a cross-sectional view of another tool that can be used to perform the friction stir processing of the present invention. -
FIG. 4 is a cross-sectional view of a material that is friction stir processed to modify the characteristics of the material. -
FIG. 5 is a cross-sectional view of a material that is friction stir processed to modify the characteristics of the material, and having an overlay identifying where a cutting edge could be formed from the friction stir processed material. -
FIG. 6 is a cross-sectional view of material that has been friction stir mixed so as to include another material. -
FIG. 7 is a cross-sectional view of one embodiment for friction stir mixing an additive material 112 into another using a mesh or screen 110 to hold the additive material 112 in place. -
FIGS. 8-66 are various industrial blades. - Reference will now be made to the diagrams of the present invention in which the various elements of the present invention will be given numerical designations and in which the invention will be discussed so as to enable one skilled in the art to make and use the invention. It is to be understood that the following description is only exemplary of the principles of the present invention, and should not be viewed as narrowing the claims which follow.
- In one aspect, the present invention provides a system and method for performing friction stir processing on an industrial blade. The friction stir processing can be performed in one embodiment on a surface of a workpiece that is fashioned into the industrial blade. In another embodiment, the friction stir processing can be performed deeper into the workpiece. In another embodiment, it is also possible to perform friction stir mixing wherein an additive element is mixed into the surface or deeper into a workpiece using a friction stir mixing tool.
-
FIG. 1 is a perspective view of a tool being used for friction stir welding that is characterized by a generallycylindrical tool 10 having ashoulder 12 and apin 14 extending outward from the shoulder. Thepin 14 is rotated against aworkpiece 16 until sufficient heat is generated, at which point the pin of the tool is plunged into the plasticized workpiece material. Theworkpiece 16 is often two sheets or plates of material that are butted together at a joint line 18. Thepin 14 is plunged into theworkpiece 16 at the joint line 18. Although this tool has been disclosed in the prior art, it will be explained that the tool can be used for a new purpose. - Another embodiment of the present invention is to use a tool as shown in
FIG. 2 .FIG. 2 is a cross-sectional view of a cylindrical frictionstir processing tool 20. The frictionstir processing tool 20 has ashank 22 and ashoulder 24, but no pin. Therefore, instead of plunging a pin into the material to be solid state processed, the shoulder is pressed against the material. Penetration by the shoulder is typically going to be restricted to the surface of the material or just below it because of the larger surface area of the shoulder as compared to the pin. - It should be noted that while the
pin 16 of thetool 10 inFIG. 1 does not have to be plunged into the material, the pin is more likely to be designed for easy penetration. Thus, because thepin 16 is more likely to have a very small surface area as compared to thetool 20 ofFIG. 2 , the pin is more likely to plunge into the material. However, it may be advantageous to use the smaller surface area of thepin 16 for processing much smaller areas of a material, even just on the surface thereof. Therefore, it is another embodiment of the present invention that surface and near-surface processing can also be accomplished using a tool that is more typically used for penetration and joining of materials. -
FIG. 3 is provided as an alternative embodiment for a tool having no pin.FIG. 3 shows atool 30 having a shank 32 that is smaller in diameter than theshoulder 34. This design can be more economical because of less material used in its construction, depending upon the diameter of theshoulder 34. - It is important to recognize that nothing should be inferred from the shape of the
shoulders FIGS. 2 and 3 . Theshoulders - Experimental results have demonstrated that the material to be used for the industrial blade may undergo several important changes during friction stir processing. These changes may include, but should not be considered limited to, the following: microstructure, macrostructure, toughness, hardness, grain boundaries, grain size, the distribution of phases, ductility, superplasticity, change in nucleation site densities, compressibility, expandability, coefficient of friction, abrasion resistance, corrosion resistance, fatigue resistance, magnetic properties, strength, radiation absorption, and thermal conductivity.
- Regarding nucleation, observations indicate that there may be more nucleation sites in the processed material due to the energy induced into the material from friction stir processing. Accordingly, more of the solute material may be able to come out of solution or precipitate to form higher densities of precipitates or second phases.
- In
FIG. 4 , a section ofATS 34 steel was friction stir processed by plunging a tool similar to the tool shown inFIG. 2 into theworkpiece 70 and moving the tool transversely along a middle length thereof. Transverse movement would be perpendicular to the page, thusFIG. 5 is a cross-sectional view of thebase material 70. -
FIG. 4 shows that the tool plunged into thebase material 70 from the top 72. Several areas appearing as small circles are shown as having been tested for hardness relative to the Rockwell scale in the various zones of the base material. Thestir zone 74 is shown having a hardness of 60 RC. Close to the boundary of the inner TMAZ (thermally mechanically affected zone) and the outer HAZ (heat affected zone) thebase material 70 is shown as having a hardness value of 44 RC at a location 76. Finally, an unprocessed or original base material zone is shown as having retained, in other samples, its original hardness value of 12 RC at approximatelylocation 78. -
FIG. 5 is an illustration of anoverlay 90 of a cutting edge on the ATS-34steel base material 70. Theoverlay 90 indicates one advantageous configuration of an industrial blade that could be machined from thematerial 70, wherein the configuration takes the greatest advantage of the improved toughness and hardness characteristics of the friction stir processedmaterial 70. Note that theindustrial blade overlay 90 is formed in the processedregion 74 that will result in a hard and yet tough cutting edge. Likewise, any object being formed from a processed material can be arranged to provide the most advantageous properties where it is most critical for the object. In this example, a beneficial cutting edge will be achieved from having an edge disposed well within the processed material. - As examples of what is possible to create using the system and methods of the embodiments of the present invention, three hand-held blades processed using a friction stir processing system and method in accordance with the present invention were prepared and tested against conventional blades. The creation of the test blades was accomplished by friction stir processing a workpiece that was then finished to form a hand-held knife blade having a profile substantially identical to a conventional knife blade used for a comparison.
- The hand-held test blades of the present invention were created by machining the hand-held test blades in accordance with the following instructions. The first attempt at grinding was to obtain a 22 degree angle with a 600 grit diamond belt. The result was a polished edge. A 320 diamond grit was then used with good results to further refine the hand-held blade. The desired angle was established and after a few passes, the cutting edge was placed against the 600 grit diamond belt to establish the desired wire “burr”. The wire burr was removed with an 8,000 grit diamond belt and then polished with a 50,000 grit diamond belt. A razor “shaving” edge was established on the test blades and the cutting edge appeared to remain totally within the processed material.
- It should be noted that the instructions provided above are only to create test blades that are comparable in sharpness to the blades that are being used for comparison purposes. An industrial blade that can be created using the friction stir processing and friction stir mixing methods of the present invention should not be considered to be limited to the parameters stated above.
- An important element of the present invention is also the concept of friction stir mixing. Whereas friction stir processing will be regarding as the processing of a single material that is to be fashioned into an industrial blade, friction stir mixing provides for additional additive materials to be included in the friction stir mixing process. The additive materials become an integral part of the resulting industrial blades.
-
FIG. 6 is a cross-sectional view of a base material that has been friction stir mixed so as to include another additive material. Specifically, a steel member 100 has been friction stir mixed so as to work in diamond particles 102 into the steel member. -
FIG. 7 is a cross-sectional view of one embodiment for friction stir mixing an additive material 112 into another using a mesh or screen 110 to hold the additive material 112 in place. Specifically, a stainless steel mesh or screen 110 is being used to hold carbide 112 in the form of a powder. The screen 110 and carbide powder 112 are disposed on the surface of a base material 114. The surface of the base material 114 is then friction stir processed, resulting in a mixing of the stainless steel 110, the carbide 112, and the base material 114 at the surface of the base material. Alternatively, the different materials could be mixed further into the base material 114 using a tool having a pin, or by using a tool having a shoulder that is pressed harder into the base material. - An important concept of the present invention is that solid state processing or friction stir processing that is performed is a temporary transformation into a plasticized state. Thus, the material that is used as the workpiece and formed into the industrial blade may not pass through a liquid state.
- The balance of this document is devoted to test results for comparisons that achieved unexpected results using hand-held blades. For comparison purposes, a Brown Bear™ hand-held Cleaver blade formed of D-2 steel was bolted to a test handle. A hand-held test blade having a cutting edge formed of friction stir processed D-2 steel ground to an identical profile was also prepared and bolted to a handle in a similar manner. The resulting hand-held cleaver blade and hand-held test blade were both 24 ounce blades that provided ample weight and inertia for chopping.
- A first chopping test was performed on a green red oak limb; a second chopping test was performed on a dried Osage orange limb, which is an extremely hard, dense wood; a third chopping test was performed on an elk antler (bone); a fourth chopping test was performed on a brick block, and a fifth chopping test was performed on a steel anvil. Results for chopping with the test blade are as follows in Table 1:
TABLE 1 Test Result Green red oak No edge chipping; edge will still shave dry hair Dried Osage No edge chipping; edge will still Orange shave dry hair Elk antler No edge chipping; minor edge wear evident; would shave wet hair Brick Edge damage evident with several small chips and dulled edge Steel anvil Small edge separation at point of machining groove for friction stir - Both hand-held cleavers were able to consistently cut through bone and hard wood without chipping. However, the hand-held test blade was found to provide greater edge retention over the conventional hand-held cleaver.
- The above tests were also performed using a hand-held Bush™ Camp Knife and a hand-held Jaeger™ Boning knife which both have good edge retention when compared to other hand-held knives. As shown in
FIG. 16 , both hand-held knives had catastrophic cutting edge failures when tested on the elk antler and, thus, were not tested on the harder materials. - A second hand-held test blade was sharpened to perform new tests. The second test blade was used to cut rope for 30 minutes. In that time, 607 cuts were made until the rope was gone. The second hand-held test blade still shaved dry hair afterwards.
- Further tests were performed on hand-held test blades, such as the sharpness test of the friction stir processed edge. For this test, five different Knives of Alaska™, Inc. hand-held knife models were first tested. These hand-held knives include the Alaskan Brown Bear Skinner/Cleaver (D2 steel; RC 55-57), the Jaeger Boning Knife (ATS-34 steel; RC 59-61), the Bush Camp Knife (AUS8 steel; RC 57-59), the Coho fisherman's knife (hollow ground AUS8 steel; RC 57-59), and the Magnum Ulu (D2 steel; RC 59-61). The final test was on a hand-held test blade with the friction stir processed edge.
- The test for sharpness involved placing a ¾ inch thick hemp rope on a 2×6 board. A section on each knife was selected and the rope was cut completely through by striking the back of the blade with a soft mallet. The rope was repeatedly cut, at the same point on the hand-held knife blade. The number of cuts was recorded for each hand-held blade. When the hand-held knife's tested section would no longer shave dry hair on the tester's arm—this was recorded as one past the maximum number of cuts that that hand-held blade steel would retain a shaving edge. The test results are as follows as shown in Table 2:
TABLE 2 Number of Cuts Where hand-held Hand-held Knife Knife No Longer Shaves Alaskan Brown Bear 17 Jaeger Boning Knife 67 Bush Camp Knife 41 Coho Fisherman's Knife 14 Magnum Ulu 52 Test Blade 100+ - It is observed that the testing of the hand-held test blade was stopped at 100 cuts as the hand-held test blade was already exceeding all other test samples. The hand-held test blade is shown in
FIG. 15 . Furthermore, the hand-held blade would still shave and there was no appreciable difference between the edge when the testing began and after 100 cuts. - The test blades formed in accordance with the present invention held up to and exceeded expectations in the sharpness category and in the impact test results. Conventionally, it is unexpected to be able to take a two pound hand-held test blade and swing it smartly to cut through a hard material such as elk antler, repeatedly, and still retain a shaving edge with no edge fracturing. Such performance is unheard of in the hand-held knife industry.
- Friction stir processing may be applied to any hand-held knife blade to enhance performance characteristics of the blades. Such hand-held knife blades may be formed of any material known in the art, including D2 steel, ATS-34 steel, AUS8 steel, S-30V steel, or other materials.
-
FIGS. 8-66 are provided as illustrations of the many different types of industrial blades that are considered to be within the scope of the embodiments of the present invention. However, the following list of industrial blades should not be considered limiting, as there are other industrial blades that can also take advantage of the benefits of the embodiments of the present invention. -
FIGS. 8-66 includes the following industrial blades: angle milling cutter, boring tools, broach, burr, chanfer cutter, circular cutting blades for food, metal or paper, converting slitters, counter bores, counter sinks, cutting tool endmill, cutting tool reamer, deburring tool, drill bit, endmill, fishing milling cutter, food processing, form cutter, gear cutting tool, gear shaper tool-shaving cutter, grooving tool, guillotine paper and food cutting blades, gun drill and reamers, helical end mill, hobs, hobs and side milling cutters, hole opener, hole saw, hydraulic pipe cutter, jaw crusher, keyseat cutter, metal working shear blades, milling cutter, packaging and cutoff knives, plastic granulating knives, press brake dies, reamer, rotaryfile cutter, round textile knife, router bit, saw blades, shear blades, shell end mills, side milling cutter, slitter blades for packaging, tap cutter, taps, textile knives, thin disk cutters, thread mill, and threading tool. This list of industrial blades should not be considered limiting, but presents a large cross-section of the various industrial blades on the market. - It is to be understood that the above-described arrangements are only illustrative of the application of the principles of the present invention. Numerous modifications and alternative arrangements may be devised by those skilled in the art without departing from the spirit and scope of the present invention. The appended claims are intended to cover such modifications and arrangements.
Claims (20)
Priority Applications (6)
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US11/090,317 US20060032333A1 (en) | 2004-03-24 | 2005-03-24 | Solid state processing of industrial blades, edges and cutting elements |
PCT/US2005/018121 WO2005113173A2 (en) | 2004-05-21 | 2005-05-23 | Friction stirring and its application to drill bits, oil field and mining tools, and components in other industrial applications |
US12/629,366 US20100071961A1 (en) | 2004-05-21 | 2009-12-02 | Bit leg outer surface processing using friction stir welding (fsw) |
US12/629,201 US20100078224A1 (en) | 2004-05-21 | 2009-12-02 | Ball hole welding using the friction stir welding (fsw) process |
US14/046,769 US8955734B2 (en) | 2004-05-21 | 2013-10-04 | Ball hole welding using the friction stir welding (FSW) process |
US14/598,657 US20150258628A1 (en) | 2004-05-21 | 2015-01-16 | Friction stirring and its application to drill bits, oil field and mining tools, and components in other industrial applications |
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US11/090,317 US20060032333A1 (en) | 2004-03-24 | 2005-03-24 | Solid state processing of industrial blades, edges and cutting elements |
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US13/479,650 Abandoned US20120227546A1 (en) | 2004-03-24 | 2012-05-24 | Solid state processing of hand-held knife blades to improve blade performance |
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US13/479,650 Abandoned US20120227546A1 (en) | 2004-03-24 | 2012-05-24 | Solid state processing of hand-held knife blades to improve blade performance |
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US8955734B2 (en) | 2004-05-21 | 2015-02-17 | Smith International, Inc. | Ball hole welding using the friction stir welding (FSW) process |
US20100078224A1 (en) * | 2004-05-21 | 2010-04-01 | Smith International, Inc. | Ball hole welding using the friction stir welding (fsw) process |
US20110077654A1 (en) * | 2004-07-27 | 2011-03-31 | Lonnie Jay Lamprich | Spinal Disc Prosthesis Apparatus and Placement Method |
US20060157531A1 (en) * | 2004-12-17 | 2006-07-20 | Packer Scott M | Single body friction stir welding tool for high melting temperature materials |
US7753252B2 (en) | 2005-05-05 | 2010-07-13 | Smith International | Method for construction of pressure vessels with a liner using friction stirring processes |
US20060255094A1 (en) * | 2005-05-05 | 2006-11-16 | Taylor Brian E | Method for construction of pressure vessels with a liner using friction stirring processes |
CN102528611A (en) * | 2010-12-24 | 2012-07-04 | 中国科学院金属研究所 | Repair method for short-process casting defects |
US10695861B2 (en) | 2014-07-10 | 2020-06-30 | Mazak Corporation | Friction stir extrusion of nonweldable materials for downhole tools |
US10799980B2 (en) | 2016-10-06 | 2020-10-13 | Mazak Corporation | Compressible friction stir welding tool for conventional machining equipment |
US11130192B2 (en) | 2017-08-30 | 2021-09-28 | Mazak Corporation | Instrumented tool handler for friction stir welding |
US12011776B2 (en) | 2017-08-30 | 2024-06-18 | Mazak Corporation | Instrumented tool handler for friction stir welding |
US11458564B2 (en) | 2017-08-31 | 2022-10-04 | Mazak Corporation | Devices, systems, and methods for increased wear resistance during low temperature friction stir processing |
US11059125B2 (en) | 2017-11-21 | 2021-07-13 | Mazak Corporation | Friction stir processing tool with radial protrusion |
US11440133B2 (en) | 2018-05-04 | 2022-09-13 | Mazak Corporation | Low-cost friction stir processing tool |
US11697173B2 (en) | 2018-05-09 | 2023-07-11 | Brigham Young University | Systems and methods for friction bit joining |
Also Published As
Publication number | Publication date |
---|---|
WO2005094542A3 (en) | 2006-11-16 |
WO2005094274A3 (en) | 2007-03-29 |
JP2007532151A (en) | 2007-11-15 |
US20050252341A1 (en) | 2005-11-17 |
US8186561B2 (en) | 2012-05-29 |
WO2005094274A2 (en) | 2005-10-13 |
US20120227546A1 (en) | 2012-09-13 |
WO2005094542A2 (en) | 2005-10-13 |
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