U.S. patent application number 09/298105 was filed with the patent office on 2001-09-20 for weld joint design for corners.
Invention is credited to MONDY, MICHAEL C..
Application Number | 20010022465 09/298105 |
Document ID | / |
Family ID | 23149053 |
Filed Date | 2001-09-20 |
United States Patent
Application |
20010022465 |
Kind Code |
A1 |
MONDY, MICHAEL C. |
September 20, 2001 |
WELD JOINT DESIGN FOR CORNERS
Abstract
A design is disclosed for promoting the formation of weld
between a first member and a second member whereby a fin is
introduced at the outer corner portion of the first member to
minimize the creation of defects such as runout or rollover. While
such a design is applicable to any industrial welding operation,
this design is of particular interest for welding bases or bit
blocks holding cutting bits onto rotatable drums, wheels or chains
used in construction or mining operations.
Inventors: |
MONDY, MICHAEL C.; (EVERETT,
PA) |
Correspondence
Address: |
JOHN J PRIZZI
KENNAMETAL INC
P O BOX 231
LATROBE
PA
15650
|
Family ID: |
23149053 |
Appl. No.: |
09/298105 |
Filed: |
April 22, 1999 |
Current U.S.
Class: |
299/102 ;
228/164; 228/214; 299/39.8; 299/79.1 |
Current CPC
Class: |
F16B 2200/30 20180801;
B23K 33/00 20130101; B23K 2101/04 20180801; B23K 2101/20
20180801 |
Class at
Publication: |
299/102 ;
299/79.1; 299/39.8; 228/214; 228/164 |
International
Class: |
E21C 035/18 |
Claims
I claim:
1. A first member for welding to a second member comprised of a
body having: a) a top and a bottom, b) a face on the bottom for
contacting a surface on the second member, c) a plurality of sides
between the top and the bottom including, i) a first side adjacent
to the face, and ii) a second side adjacent to the face, d) wherein
the first side and the second side converge to define an outside
corner region between the top and the bottom, and e) a fin
extending from the corner region to promote the formation of a weld
in the corner region.
2. The member according to claim 1 wherein the first side and
second side converge to form a corner angle between
10-150.degree..
3. The member according to claim 2 wherein the corner angle is
90.degree..
4. The member according to claim 1 wherein the corner region is
defined by the borders of the segments of the first and second
sides extending from the point of intersection of the first side
and the second side back a distance of less than 1/4 the length of
the respective side.
5. The member according to claim 1 wherein the corner region is
defined as a transition segment connecting the first side and the
second side.
6. The member according to claim 1 wherein the fin is integral with
the body.
7. The member according to claim 1 wherein the fin is a separate
piece attached to the body.
8. The member according to claim 1 wherein the fin is vertically
spaced from the bottom of the body.
9. The member according to claim 1 wherein the shape of the fin is
polygonal.
10. The member according to claim 9 wherein the shape of the fin is
triangular.
11. The member according to claim 9 wherein the shape of the fin is
quadrilateral.
12. The member according to claim 1 wherein the fin has a thickness
and a width wherein the thickness is less than 1/4 of the maximum
width of the fin.
13. The member according to claim 1 wherein two opposing vertical
walls and a line extending between the vertical walls form a fin
angle of between 0-45.degree. with a line extending from one side
of the body.
14. The member according to claim 13 wherein the fin angle is
45.degree..
15. The member according to claim 1 wherein at least one side of
the body has a chamfer in the bottom of that side in the corner
region and the fin extends from the chamfer in that side.
16. The member according to claim 1 wherein the first member and
the fin are made of metal.
17. A system of a first member secured to a second member by a weld
comprising: a) the second member having a mounting surface, b) the
first member having, 1) a top and a bottom, 2) a face on the bottom
for contacting the mounting surface on the second member, 3) a
plurality of sides between the top and the bottom, including, i) a
first side adjacent to the face, and ii) a second side adjacent to
the face, 4) wherein the first side and the second side converge to
define an outside corner region between the top and the bottom, and
5) a fin extending from the corner region, c) weld material
extending around the fin and between the first member and the
second member in the corner region.
18. The system according to claim 17 wherein the first side of the
first member and the second side of the first member converge to
form a corner angle of between 10-150.degree..
19. The system according to claim 18 wherein the corner angle is
90.degree..
20. The system according to claim 17 wherein the corner region is
defined by the borders of the segments of the first and second
sides extending from the point of intersection of the first side
and the second side back a distance of less than 1/4 the length of
the respective side.
21. The system according to claim 17 wherein the corner region of
the first member is defined as a transition segment connecting the
first side and the second side.
22. The system according to claim 17 wherein the fin is integral
with the first member.
23. The system according to claim 17 wherein the fin is a separate
piece attached to the first member.
24. The system according to claim 17 wherein the fin is vertically
spaced from the bottom of the first member.
25. The system according to claim 17 wherein the fin is attached to
the second member.
26. The system according to claim 25 wherein the fin is mounted
upon the second member in a position horizontally spaced from the
first member.
27. The system according to claim 17 wherein the shape of the fin
is polygonal.
28. The system according to claim 27 wherein the shape of the fin
is triangular.
29. The system according to claim 27 wherein the shape of the fin
is quadrilateral.
30. The system according to claim 17 wherein the fin has a
thickness and a width wherein the thickness is less than 1/4 of the
maximum width of the fin.
31. The system according to claim 17 wherein the fin has two
opposing vertical walls and a line extending between the vertical
walls form a fin angle of between 0-45 degrees with a line
extending from one side of the first member.
32. The system according to claim 31 wherein the fin angle is
45.degree..
33. The system according to claim 17 wherein at least one side of
the first member has a chamfer in the bottom of that side in the
corner region and the fin extends from the chamfer in that
side.
34. The fin system according to claim 17 wherein the first member,
the second member and the fin are made of metal.
35. A metal base for welding to a rotatable metal member used for
mining or construction operations, wherein the base secures a
cutting bit and wherein the base has a body which is comprised of:
a) a top and a bottom, b) a face on the bottom for contacting a
surface on the rotatable member, c) a plurality of sides between
the top and bottom including, i) a first side adjacent to the face
and ii) a second side adjacent to the face, d) wherein the first
side and the second side converge to define an outside corner
region between the top and the bottom, and e) a metal fin extending
from the corner region to promote the formation of a proper weld in
the corner region between the base and the rotatable member.
36. The base according to claim 35 wherein the first side and
second side converge to form a corner angle between
10-150.degree..
37. The base according to claim 36 wherein the corner angle is
90.degree..
38. The base according to claim 35 wherein the corner region is
defined by the borders of the segments of the first and second
sides extending from the point of intersection of the first side
and the second side back a distance of less than 1/4 the length of
the respective side.
39. The base according to claim 35 wherein the corner region is
defined as a transition segment connecting the first side and the
second side.
40. The base according to claim 35 wherein the fin is integral with
the base.
41. The base according to claim 35 wherein the fin is a separate
piece attached to the base.
42. The base according to claim 35 wherein the fin is vertically
spaced from the bottom of the base.
43. The base according to claim 35 wherein the shape of the fin is
polygonal.
44. The base according to claim 43 wherein the shape of the fin is
triangular.
45. The base according to claim 43 wherein the shape of the fin is
quadrilateral.
46. The base according to claim 35 wherein the fin has a thickness
and a width wherein the thickness is less than 1/4 of the maximum
width of the fin.
47. The base according to claim 35 wherein two opposing vertical
walls and a line extending between the vertical walls forms an fin
angle of between 0-45.degree. with a line extending from one side
of the base.
48. The base according to claim 47 wherein the fin angle is 45
degrees.
49. The base according to claim 35 wherein at least one side of the
base has a chamfer in the bottom of that side in the corner region
and the fin extends from the chamfer in that side.
50. A system of a metal base secured on a rotatable metal member
used for mining or construction operations wherein the base secures
a cutting bit and wherein the system is comprised of: a) the
rotatable metal member having a mounting surface, b) the metal base
made of a body having: 1) a top and a bottom, 2) a face on the
bottom which contacts the mounting surface of the rotatable member,
3) a plurality of sides between the top and the bottom with each
side adjacent to two other sides, 4) wherein at least a first side
and a second side define one pair of adjacent sides which converge
to define at least one outside corner region between the top and
the bottom, 5) a metal fin extending from the at least one corner
region to promote the formation of a proper weld in the corner
region, and c) weld material extending substantially around the
base between the mounting surface of the rotatable member and the
sides of the base, wherein the welding material in the at least one
corner region is applied to a depth sufficient to cover the
fin.
51. The system according to claim 50 wherein the first side of the
base and the second side of the base converge to form a corner
angle of between 10-150.degree..
52. The system according to claim 51 wherein the corner angle is
90.degree..
53. The system according to claim 50 wherein the corner region is
defined by the borders of the segments of the first and second
sides extending from the point of intersection of the first side
and the second side back a distance of less than 1/4 the length of
the respective side.
54. The system according to claim 50 wherein the corner region of
the block is defined as a transition segment connecting the first
side and the second side.
55. The system according to claim 50 wherein the fin is integral
with the body of the base.
56. The system according to claim 50 wherein the fin is a separate
piece attached to the body of the base.
57. The system according to claim 50 wherein the fin is vertically
spaced from the bottom of the body of the base.
58. The system according to claim 50 wherein the fin is attached to
the surface of the rotatable member.
59. The system according to claim 58 wherein the fin is attached to
the rotatable member in a position horizontally spaced from the
base.
60. The system according to claim 50 wherein the shape of the fin
is polygonal.
61. The system according to claim 60 wherein the shape of the fin
is triangular.
62. The system according to claim 60 wherein the shape of the fin
is quadrilateral.
63. The system according to claim 50 wherein the fin has a
thickness and a width wherein the thickness is less than 1/4 of the
maximum width of the fin.
64. The system according to claim 50 wherein the fin has two
opposing vertical walls and a line extending between the vertical
walls form an fin angle of between 0-45.degree. with a line
extending from one side of the body.
65. The system according to claim 64 wherein the fin angle is 45
degrees.
66. The system according to claim 50 wherein at least one side of
the body of the base has a chamfer in the bottom of that side in
the corner region and the fin extends from the chamfer.
67. The system according to claim 50 wherein the rotatable member
may be a rotatable drum, wheel or chain.
68. The system according to claim 50 wherein there are at least one
hundred metal bases welded to the rotatable member.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to a design to promote welding in
corner regions and more particular to the use of a fin extending
outwardly from an outside corner region to promote the proper
formation of a weld around such a corner region.
[0003] 2. Description of the Related Art
[0004] Welding is defined as the process of uniting two members by
heating them until they are molten and fused, with or without the
use of a filler material.
[0005] The focus of this application will be directed to welding
utilizing a filler material to join two parts which intersect at a
corner and for which weld filler must be used to produce a
continuous weld around the corner.
[0006] Manual welding typically is labor intense and requires a
high level of skill on behalf of the welder to efficiently produce
a strong high quality weld. Because there are frequently great
demands for production placed upon a welder, there is always a
desire to improve efficiency by either improving the manner in
which the weld is laid or by providing a design which requires less
weld material. A design which may permit both of these beneficial
features is highly desirable.
[0007] Welding material around the corner of a workpiece presents
unique problems to which the subject invention is directed. As an
example, FIG. 1, which is prior art, illustrates a system by which
a first member 10 is secured to a second member 15 by a weld 20.
The first member 10 has at least a first side 25 and a second side
30. Each side has an upper portion 32 and a lower portion 34
wherein the lower portion 34 is chamfered relative to the upper
portion 32. The weld 20 is fused to the lower portion 34 of at
least the first side 25 and the second side 30 of the first member
10. The weld 20 is additionally fused to the surface 35 of the
second member 15 thereby securing the first member 10 to the second
member 15.
[0008] Although defects associated with welding may occur along any
portion of the weld 20, the outside corner portions of welds seem
to more frequently have defects. The first member 10 which is
illustrated as a solid piece, has only outside corners 36, 37, 38,
39. To put this in perspective, if the first member 10 was hollowed
out to form a cavity having a perimeter of the same shape as the
exterior of the first member 10, the enclosed corners would be
referred to as inside corners.
[0009] FIG. 2 illustrates a section view of the corner portion of
the weld along arrows "2-2" in FIG. 1. The lower portion 34 of the
side 25 is not illustrated in either this view or the view to be
discussed with FIG. 3. In FIG. 2, the bottom face 40 of the first
member 10 contacts the surface 35 of the second member 15. Weld 20
is used to attach the first member 10 to the second member 15. The
metal filler of the weld 20 penetrates the side 25 of the first
member 10 and simultaneously penetrates the surface 35 of the
second member 15. However, it is not uncommon when welding a corner
region to produce a defect known as a rollover, which is also
called an overlap. Such a defect is associated with fillet welds
and can be produced when either the current of an arc welding
machine is too low to properly fuse the second member 15 or the
travel speed for the welding process is too low to accept the
amount of metal filler being deposited. As a result, a portion of
the weld 20 merely flows onto an area of surface 35 and does not
fuse with the surface 35. The rollover portion, which is indicated
by 50 must be removed to ensure the integrity of the weld 20. Such
a defect must be removed by grinding, which requires additional
time and labor.
[0010] Another type of weld defect which is not uncommon in corner
regions is illustrated in FIG. 3 and is referred to as an undercut.
FIG. 3 is a view similar to FIG. 2 illustrating a different defect.
An undercut is an irregular gouge which is generally found in the
upper toe of a horizontal fillet weld. With reference to FIG. 3,
the first member 10 has a bottom face 40 which contacts the surface
35 of the second member 15. However, in this situation, the weld 20
droops from a recess or undercut 55 produced in the side 25 of the
first member 10. The side 25 of the first member 10 has been melted
but has not been refilled with weld material. Most often this
defect is caused by improper selected welding conditions such as
the electrode angle, travel speed and welding current. It is more
likely to occur when attempting to make fillet welds with legs that
are more than 0.3 inches in length. Just as a with a rollover
defect however, such defects are unacceptable if the integrity of
the weld is to be maintained and such defects must be removed.
These defects in welds on outside corners may be avoided but only
at the cost of a significant increase in welding time and
expense.
[0011] U.S. Pat. No. 3,832,523 discloses a method for electrical
arc welding. In FIG. 12 of that patent, a segment 50 is illustrated
which is used on a vertical section for preventing a resulting weld
bead which is not completely solidified from drooping. Segment 50
acts as a physical barrier to the weld material. As a result, the
section on the plates under segment 50 will not be covered with
weld material and therefore the weld will not be continuous.
Furthermore, the weld does not extend around a corner and many
applications require a continuous bead of weld material around a
corner.
[0012] U.S. Pat. No. 4,208,563 illustrates a welding method using a
break away flux dam in which copper wires are used to surround the
weld area and create a pool of molten weld metal with a top layer
of flux. While this illustrates a manner of containing a weld, it
once again does not address a weld around a corner with a
continuous bead of weld material.
[0013] A design is needed which permits a welder to secure a first
member, which may be metal, having outside corners to a second
member, which also may be metal, while applying a continuous weld
around the corners of the member in an expedient fashion that will
provide a weld with integrity and minimize the potential for
producing defects such as rollover and undercut while also reducing
the time and cost of welding.
[0014] While such a design is applicable to welding any two members
with outside corners, it is of particular significance in securing
a bit block or base to a rotatable member, such as a drum, wheel or
chain, for equipment used in construction operations, such as road
planning or trenching, or in mining operations, such as coal
mining.
BRIEF SUMMARY OF THE INVENTION
[0015] One embodiment of the invention is directed to a first
member for welding to a second member wherein the first member is
comprised of a body having a top, a bottom and a face on the bottom
for contacting a surface on the second member. The first member has
a plurality of sides between the top and the bottom including a
first side adjacent to the face, and a second side adjacent to the
face. The first side and the second side converge to define an
outside corner region between the top and the bottom. A fin extends
from the corner region to promote the formation of a weld in the
corner region.
[0016] A second embodiment of the invention is directed to a system
which includes the first member just described mounted upon a
second member using weld material.
[0017] A third embodiment of the invention is directed toward one
application of the first member as a metal block for mounting upon
a metal drum used in mining or construction operations.
[0018] A fourth embodiment of the invention is directed toward one
application of a system including the first member as a metal block
mounted to a metal drum and secured with weld material for use in
mining or construction operations.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 is prior art and illustrates a perspective view of a
first member secured to a second member with a weld;
[0020] FIG. 2 is prior art and illustrates a cross-sectional view
along arrows "2-2" in FIG. 1 highlighting a weld defect;
[0021] FIG. 3 is prior art and illustrates a view similar to FIG. 2
highlighting a different weld defect;
[0022] FIG. 4 is a perspective view of a first member to be secured
to a second member by welding and incorporating a design in
accordance with the subject invention;
[0023] FIG. 5A illustrates a top view of the arrangement in FIG. 4
in which the first member has radiussed corners;
[0024] FIG. 5B illustrates a variation of the view in FIG. 5A in
which the first member has square corners;
[0025] FIG. 6 is a cross-sectional view of a corner illustrated by
arrows "6-6" in FIG. 4 in accordance with the subject
invention;
[0026] FIGS. 6A, 6B, 6C and 6D are cross-sectional views similar to
FIG. 6 but showing different embodiments of the subject
invention;
[0027] FIG. 7 is a portion of the plan view illustrated along
arrows "7-7" illustrated in FIG. 4;
[0028] FIGS. 7A and 7B are plan views showing different embodiments
of the design illustrated in FIG. 7;
[0029] FIG. 8 is a perspective view illustrating a first member
attached to a second member having fins extending from within the
first member;
[0030] FIG. 9 is a sectional view of the corner region along arrows
"9-9" in FIG. 8;
[0031] FIG. 10 is a bottom view of the first member illustrated in
FIG. 8;
[0032] FIG. 11 illustrates a perspective view of a first member
which is a base incorporating the subject invention and secured to
the surface of a second member, which is a rotatable member, used
for mining or construction operations;
[0033] FIG. 12 is a bottom view of the base illustrated in FIG.
11;
[0034] FIG. 13 illustrates a perspective view of a first member
which is a base incorporating another embodiment of the subject
invention and secured to the surface of a second member, which is a
rotatable member, used for mining or construction operations;
[0035] FIG. 14 is a side view of the base illustrated in FIG.
13;
[0036] FIG. 15 is a bottom view of the base illustrated in FIG. 13;
and
[0037] FIG. 16 is a partial section view illustrated along arrows
"16-16" in FIG. 14.
DETAILED DESCRIPTION OF THE INVENTION
[0038] The subject invention is directed to outwardly extending
fins in the outer corner region of a first member secured to a
second member by welding. By providing a fin in the body of the
weld, the weld material will have additional surface on which to
adhere. This additional surface provides support to the weld when
in a fluid condition thereby minimizing defects such as rollover or
undercut in or near the corner regions.
[0039] Welding which is appropriate to secure the first member to
the second member, may be any number of different weld methods
including arc welding, gas welding or any other welding method
which deposits a filler between two pieces to be joined.
[0040] Additionally, while the subject invention will be
illustrated using a single fillet weld on a tee joint, it should be
appreciated the subject invention may be useful for many other
types of welds including a single level groove, a single J-groove
or any other weld type suitable for a tee joint in which an outside
corner must be welded.
[0041] FIG. 4 illustrates a perspective view of a first member 110
attached to a second member 115 on the surface 117 of the second
member 115. The first member 110 has a body 112 and a top 120 and a
bottom 122 with a bottom face 125 and a plurality of sides 130,
135, 140 and 145 and outside corners 150, 155, 160, 165 between the
top 120 and bottom 122. While the first member 110 illustrated in
FIG. 4 has four sides 130, 135, 140 and 145 and four outside
corners 150, 155, 160, 165 the subject invention will be directed
to only an outside single corner 150 with the understanding that
the invention may be applicable to any outside corners including
the remaining three illustrated in FIG. 4. For that reason, side
130 will be referred to as the first side 130 and side 135 will be
referred to as the second side 135.
[0042] While the body 112 in FIG. 4 is quadrilateral, attention
will be directed to one outside corner and it should be appreciated
the subject invention may be applied to a first member 110 having
any number of different shapes in so much as any of these shapes
has at least one outside corner in which a continuous weld is
required.
[0043] The first side 130 and the second side 135 are adjacent to
the bottom face 125. Furthermore, the first side 130 and the second
side 135 converge to define an outside corner region highlighted by
the dotted line labeled 170 between the top 120 and bottom 122.
[0044] A fin 175 extends from the outside corner region 170 to
promote the formation of a weld (not shown) in the outside corner
region 170. The first side 130 and the second side 135 converge to
form a corner angle A which, although shown as approximately
90.degree. in FIG. 4, may actually have a range between 10.degree.
to 150.degree.. The first member 110, second member 115 and fin 175
are all made of materials which are compatible for welding
together. As an example, all of the parts may be weld compatible
metal. The weld material must also be selected to be compatible
with these parts.
[0045] Turning attention to FIG. 5A, the outside corner region 170
is defined with a transition segment 180 connecting the first side
130 with the second side 135. FIG. 5B illustrates a different
arrangement in which there is no transition segment but has a
corner region 170 bordered by first side segment 190 and second
side segment 195. Fin 175 is removed from one corner for
illustration clarity. The first side 130 has a length L1. The
second side 135 has a length of L2. The first side 130 and second
side 135 intersect at intersection point 185. The first side
segment 190 extends from the intersection point 185 back along the
first side 130 a distance of L1/4 or less. The second side segment
195 extends from the intersection point 185 back along the second
side 135 a distance of L2/4 or less.
[0046] Therefore, the corner region 170 may be comprised of the
intersection of the first side 130 and second side 135 through a
transition segment 180 as illustrated in FIG. 5A or may be
comprised of the region proximate to the intersection of the first
side 130 and the second side 135. It should be noted that on FIG.
5A the transition segment 180 is illustrated as a curved segment
but that this segment may also be straight.
[0047] FIG. 6 illustrates the fin 175 as a separate piece attached
to the body 112. Such an attachment may be through a tack weld or
other conventional means for attaching. A weld 20 is illustrated in
phantom to show the relative position of the weld 20 relative to
the fin 175.
[0048] FIG. 6A illustrates another embodiment in which the fin 175
is not a separate piece but is an integral part of the body 112 of
the first member 110 which can be formed when the body 112 itself
is formed by casting or forging or may be subsequently machined or
ground into a casted or formed part.
[0049] In still another embodiment, the fin 175 may be an integral
part of the body 112 or may be a separate piece attached to the
body 112 but, in either case as illustrated in FIGS. 6B and 6C, the
fin 175 may be vertically spaced from the bottom 120 of the body
112.
[0050] Although the fin 175 has been illustrated as having a
triangular configuration, the fin 175 may also have any of a wide
variety of polygonal shapes including a quadrilateral shape as
illustrated in FIG. 6D.
[0051] Briefly returning to FIG. 4, the fin 175 may have a
thickness "t" and a width "W" wherein the thickness t is less than
1/4 of the width W of the fin 175 when the width W is the maximum
width at any part of the fin 175.
[0052] Directing attention to FIG. 7, the fin may have two opposing
vertical walls 177, 179 and a fin line 215 extending between them
to form a fin angle B with a line 220 extending along one side 130
of the body 112. As illustrated in FIG. 7, the fin angle B is
approximately 45.degree. however may have a value of between
0-45.degree..
[0053] As illustrated in FIG. 7A, which is an alternate embodiment
of the arrangement in FIG. 7, it is possible to mount the fin 175
upon the surface 117 of the second member 115 adjacent to the body
112 of the first member 110. The fin 175 may also be spaced a fin
distance D from the body 112. When the fin 175 is spaced from the
body 112 of the first member 110, the length of the fin 175 and fin
distance D must be considered together such that the intended weld
will completely enclose the area of the fin 175.
[0054] As previously discussed in conjunction with FIG. 7, the fin
175 may be oriented along the line 215 through the fin 175 to form
the fin angle between 0.degree.-45.degree. with a line extending
along the firs side 130. FIG. 7B illustrates such an arrangement in
which the fin angle B is 0.degree..
[0055] So far each embodiment of the subject invention has
illustrated the fin 175 extending outwardly from the outermost
perimeter of the body 112. However, it is possible for the
underside of the member to have a chamfer and the fin 175 to be
recessed within the chamfer such that it extends outwardly from
within the body 112.
[0056] FIG. 8 illustrates a perspective view of a first member 310
having a body 312 mounted to a second member 315 by weld material
(not shown). The second member 315 has a surface 317. The body 312
has a top 320 and a bottom 322 including a bottom face 325 which
rests against the surface 317 of the second member 315. The base
has sides 330, 335, 340, 345 with associated corners 350, 355, 360,
365.
[0057] Just as before, the body 312 may have any number of a
variety of different shapes and for purposes of describing the
subject invention, side 330 will be referred to as the first side
330 and side 335 as the second side 335 which meet to define an
outside corner region 370 similar to that described in previous
embodiments.
[0058] The embodiment illustrated in FIG. 8 is different from
previous embodiments in that, as illustrated in FIG. 9, which is a
section view along arrows "9-9" in FIG. 8, the side 330 is
comprised of an upper portion 332 and a lower portion 334 which is
chamfered inwardly from an upper portion 342. The chamfer on the
lower portion 334 creates a cavity 372 beneath the perimeter of the
body 312 which permits a greater amount of weld material to be used
in securing the first member 310 to the surface 317 and the second
member 315. A fin 375 may be positioned proximate to the chamfer on
the lower portion 334 in the corner region 370 to promote the
formation of a weld 321.
[0059] FIG. 10 illustrates a bottom view of the first member 310 in
FIG. 8 and shows the bottom 322 with the bottom face 325 and the
lower portion 334 extending from the sides 330, 335, 340 and 345 to
define the chamfer on the lower portion 334.
[0060] What has so far been described is a first member secured to
a second member utilizing outwardly extending fins to promote the
formation of a weld. It should be understood that such a design can
be applied to a wide number of designs in which one piece is welded
to another piece and in which it is necessary to have weld material
around an outside corner associated with these pieces.
[0061] While many practical applications for this invention may be
found, one particular application is illustrated in FIGS. 11-12 in
which a base 410 holding a bit block 411 with a cutting bit (not
shown), wherein the base 410 is secured to the surface 417 of a
rotatable member 415, such as a rotatable drum, used in mining or
construction operations. A similar arrangement without fins is
disclosed in U.S. Pat. No. 4,542,943 which is hereby incorporated
by reference. In the present design, both the base 410 and
rotatable drum 415 are metal. The base 410 has fins 475 similar to
those discussed previously with FIGS. 8-10. For illustrative
purposes, base 410 is shown without weld material securing the base
410 to the rotatable drum 415 while base 410' is shown with weld
material 419 securing the base 410' to the rotatable drum 415. One
or more bases 410 may be secured to the rotatable drum 415 in this
manner. One hundred or more bases may be welded upon larger
rotatable drums 415.
[0062] Throughout this application reference will be made to a base
welded to a rotatable drum for mining or construction operations.
The invention should not be limited to this embodiment. While
frequently the base is welded directly to the rotatable drum and a
bit block is secured within the base, the bit block itself may be
welded directly to the rotatable drum and in this arrangement the
bit block actually performs as a base. For that reason, the term
"base" is intended to cover both the base when it is welded
directly to the drum or the bit block when it is welded directly to
the drum.
[0063] Furthermore, the base or bit block may be welded to another
rotatable member other than a drum such as a rotatable wheel or
chain. However, for purposes of this discussion, reference will be
made to a base welded to a rotatable drum with the understanding
that such terminology is not intended to be limiting.
[0064] FIG. 12 illustrates a bottom view of the base 410 in FIG.
11. Specifically, the base 410 has a body 412 with a top (not
shown) and a bottom 422. The bottom 422 has a bottom face 425 which
contacts the surface 417 of the rotatable drum 415. The bottom 422
of the body 412 generally follows the contour of the surface 417 of
the rotatable drum 415, which is cylindrical.
[0065] Locating bores 480, 485 may be used with mating pins (not
shown) to position the base 410 upon the rotatable drum 415.
[0066] Many of the features in FIG. 12 are identical to those
already illustrated in FIG. 10 including first side 430, second
side 435 and sides 440, 445 which define outside corners 450, 455,
460, 465. Sides 430 and 435 intersect to define an outside corner
region 470 which includes an outwardly extending fin 475 with
similar features as those previously discussed.
[0067] FIGS. 13-16 illustrate an embodiment similar to that
discussed in FIG. 7B in which at least one fin forms a fin angle B
of 0.degree. with a line extending parallel to one of the sides of
the base. Specifically, FIG. 13 illustrates a base 510 with a bit
block 511 for use in mining or construction operations, wherein the
base 510 is secured to a surface 517 of a rotatable drum 515 used
in mining or construction operations. The base 510 has fins 575
similar to those discussed previously with FIGS. 11 and 12. For
illustrative purposes, the base 510 is shown without weld material
securing the base 510 to the rotatable drum 515 while base 510' is
shown with weld material 519 securing the base 510' to the
rotatable drum 515.
[0068] FIG. 14 illustrates a side view of the base 510 illustrated
in FIG. 13. The base 510 has a body 512 a top 520 and a bottom 522
with a bottom face 525 which contacts the surface 517 of the
rotatable drum 515. As illustrated in FIG. 15 which shows a bottom
view of the body 512 in FIG. 14, the body 512 has four sides 530,
535, 540, 545 and respective corners 550, 555, 560, 565. Each side
may be comprised of an upper portion 532 and a lower portion 534.
In a fashion similar to that discussed with respect to FIGS. 8 and
9, the lower portion 534 of each side may be chamfered such that
the fin 575 extends outwardly from this chamfered surface thereby
permitting the fin 575 to extend outwardly within the perimeter of
the body 512.
[0069] Locating bores 580, 585 may be used with mating pins (not
shown) to position the base 510 upon the rotatable drum 515.
[0070] FIG. 16 illustrates a section view along arrows "16-16" in
FIG. 14 to highlight the upper portion 532 and the lower portion
534 of side 530 in FIG. 14. As illustrated, the fin 575 extends
from the lower portion 534. The fin 575 may terminate at the
periphery of the body 512 or, although not shown, may extend beyond
the periphery of the body 512.
[0071] While the base 510 and the rotatable member 515 may be
welded in a variety of different ways using different material, one
manner of welding the base 510 to the rotatable member 515 is as
follows.
[0072] The base 510 may be made of a steel such as AISI 4140, AISI
4340, AISI 8640 or AISI 8740. In the event AISI 8740 steel is used,
it may be quenched and tempered to a Rockwell Hardness of between
40-45 RW "C".
[0073] The rotatable member 515 may be made of AISI 1018 or AISI
1020 steel.
[0074] The weld may be laid with GMAW (Gas Metal Arc Welding) using
7000 series flux core welding wire protected during welding by an
inert gas such as carbon dioxide. The welding wire may be, for
example, TR70 welding wire available from the Hobart Company or
Dual Shield 7100 Ultra welding wire available from the Esap Company
or equivalent welding wire from another manufacturer. A GMAW
welding machine (MIG) may be used set at between 21-26 volts using
{fraction (1/16)} inch weld wire fed at a rate suitable for
amperage between 185-285 Amps.
[0075] The weld may also be laid with SMA (Shielded Metal Arc
Welding) using stick electrodes available from the Hobart Company
as 7018 or 7018-M stick electrodes or equivalent stick electrodes
from another manufacturer with a suitable welding machine.
[0076] A typical base would have a side with a length of about 3
inches and a chamfer at the bottom of the side. To lay the weld,
two reverse passes are typically required. In the first pass, which
is a root pass, an approximate 1/4 inch width of weld material is
deposited in a single direction between the base and the rotatable
member at the bottom of the chamfer. In the second pass, which is
the fillet pass, a fillet weld of between 5/8-3/4 inches is
deposited in the opposite direction with a fillet oscillating pass
over the root pass material. While two reverse passes are suitable
for many applications, when additional weld material must be laid,
additional weld passes are necessary.
[0077] Further included within the subject invention and discussed
with respect to FIG. 4, is a method for attaching a first member
110 to a surface 117 of a second member 115 wherein the first
member has a top 120 and a bottom 122. The bottom 122 has a bottom
face 125 for contacting the mounting surface 117 of the second
member 115. The first member 110 may have a plurality of sides 130,
135, 140, 145 between the top 120 and the bottom 122. However, for
the purposes of the subject invention only, two adjacent sides are
necessary and for that reason, reference will be made to a first
side 130 adjacent to the bottom face 125 and a second side 135
adjacent to the face 125. The first side 130 and the second side
135 converge to define an outside corner region 170 between the top
120 and the bottom 122.
[0078] The method for attaching the first member 110 to the
mounting surface 117 of the second member 115 is comprised of the
steps of attaching a fin 175 to the first member so that the fin
175 extends from the corner region 170. The fin 175 may be attached
by tack welding or by any other attachment method which would
secure the fin 175 to the first member 110 during a welding
operation. The first member 110 is then positioned upon the surface
117 of the second member 115 and welded along at least the first
side 130 and second side 135 of the member 110 and along the
surface 117 of the second member 115 adjacent to the member in the
corner region 170 until the weld material covers the fin 175.
[0079] By incorporating the design of the present application into
metal bases for welding onto rotatable drums used in mining or
construction applications, quality welds can be readily made not
only at the drum manufacturer but also out in the field. The time
required to weld a base has been reduced by approximately 1/3. This
produces a significant cost savings when one considers welding
large numbers (e.g. 100 or more) of bases onto a drum or the cost
of downtime in the field when a drum is being repaired.
[0080] It is thought that the present invention and many of its
intended advantages will be understood from the foregoing
description and it will be apparent that various changes may be
made in the form, construction and arrangement of the parts thereof
without departing from the spirit and the scope of the invention or
sacrificing all of its material advantages, the form herein before
described being merely preferred or exemplary embodiments
thereof.
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