A newly discovered method has been revealed as a substitute for conventional dressers for fitting a single resistant stainless steel tip and a matching round end. The new way discloses a circumferential cutting shoulder to a single circular steel point, which is a critical design consideration in building a circular dresser. This new method for fitting a single resistant stainless steel tip into a circular resistive surface requires no surface modifications, since the surface design is essentially constant. In conventional dresser fitting, the size of the resistant steel tip changes as the size of the dresser increases. In this new method, however, the size of the resistive point remains constant, so that circular dressers can be adapted to fit into any size of resistive surface, including circular and rectangular shapes, without modifying the internal points of contact.
One of the major advantages of the new tip dresser is its ease of use. Since the first holder is mounted at the base of the table, there are no special tools or skills needed for this fixture. It is simply fitted over the work surface with the help of eight screws. Once installed, the work is done, and the circular dresser looks like a normal piece of furniture.
The new tip dresser also saves considerable counter space by using a compact steel rectangular box that serves as the first cutter and the second holder for the tip end of the dresser. When installed, there are only six screws to handle the entire assembly. The second cutter can be easily mounted on the wall outside the workroom by means of a short flexible pipe. The first cutter and the second holder are then installed in the same way as the conventional dressers. The work now lies within a small circle, rather than in the circle of the ordinary dresser.
This type of dresser is useful for cutting cylindrical shapes, since it can be conveniently set up and carried away when not in use. It is not at all difficult to manufacture a good distal end surface of standard size that fits perfectly into the slot that forms a base for the tip dresser assembly. All that is required is the spinning of the cylindrical member in a mandrel tool to form the desired cutting surface. The welding of the edges of the cylinder into the base material also takes place without any difficulty, as is shown by the photographs.
The method of dressing welded electrode tips is similar to that used for fabric welding, and the basic method for fitting the electrical leads to the dressers is the same. The main differences lie in the selection of electrodes that are of standard diameter and wire gauges. Dressing of these electrodes is done by welding them to the base material with the help of a torch.
A final option of dressing of electrical leads is done in the form of electroplating. Electroplating is basically an alloying process in which two different metals are combined with the cathode of one of them being immersed in the solution to form the desired metal object. The rusted areas and the plain areas are joined together by electrochemical means, and the entire object is then painted with a particular metal that is used for the final purpose. Electroplating is the most commonly used method of fitting different sizes and shapes of electrode tips to create complex and well detailed dressers.