How to Select a Cutter & Holder

Steps to Identify the Cutter & Holder for Your Application

1. Spot Weld Tip Dresser Type

The user must identify what type of tip dresser they plan to use or are using. If using a Changer & Dresser or Kyokutoh brand tip dresser, there are two different styles: a screw on holder (most common in the US) and a one touch twist lock holder (most common in Europe and Asia).

If using a non-C&D tip dresser, we can still supply cutter and holders, but we will need to know a little more information. If this is the case, please reach out to our sales team and we can assist you to accommodate your needs.

2. Upper and Lower Electrode Profile

After the tip dresser type is identified, the electrode profile should be confirmed. Electrode profiles typically will come in a few different configurations. The easiest way to get a profile is to supply a cap drawing with the upper and lower electrode cap part numbers identified (if they are different).

If you do not have a cap profile, that is okay! We will work with you to get the information that is needed to create one. Below is a general set of parameters to help us design or select a cutter and holder for your application.

Cap Diameter
Cap Shape (B-nose, A-nose, Flat, Truncated, Eccentric, Stepped)
Cap Length
Cap Weld Face and Corner Radius (if applicable)
Cap Weld Face Curvature (if non-standard curvature required)

3. Weld Gun Profile

The weld gun profile may affect the cutter and holder design and tip dresser type if the weld shanks are angled or if the clearance is limited.

We have tight clearance tip dressers which utilize a smaller diameter holder and special cutter/holder designs if the shank angle is greater than 15 degrees.

Our standard cutter and holders will be compatible with shank angles of 0-15 degrees. We recommend pairing the shank angle with the cutting profile. If a weld gun with 0 degrees upper and lower shanks is dressed using a cutting profile meant for 30 degrees, it may dress the electrodes, but the quality cannot be guaranteed. It is likely the electrodes will have poor tip dresses due to the mismatch of the shank angle.

4. Cutter Durability Required & Workpiece Material

The cutter durability must be considered if welding a high strength material or if the user wishes to reduce the frequency of cutter changes.

When spot welding high strength materials, some of the material is transferred onto the electrode weld faces. When the spot welding gun proceeds to tip dress, the tip dresser cutter shaves the same residual work piece material off of the electrodes. Therefore, in applications where the electrodes are welding harder materials, or cooling of the electrodes is poor, one of our more durable cutters is recommended.

In applications where build up occurs rapidly, we recommend using a higher durability blade, as the cutter wear occurs on a per dress basis.

Cutter Blade Types

There are many variations of cutter blades, however here is a brief summary of the types that Changer & Dresser/Kyokutoh offer.

For KTW/KTWHL Types

Standard KTW Cutter

Average durability, ideal for standard steel welding applications
Aim to replace the cutter every 6 months and the holder annually

Carbide KTW Cutter

Better durability, ideal for all applications, and best for high strength steel and aluminum welding applications
Aim to replace the cutter every 9-12 months and the holder annually

Update Your Holder Annually

The holder should be replaced every 12-18 months or when the holding surface is significantly worn. The holder is what performs most of the stabilizing of the system, so if it is not replaced regularly, tip dress issues can occur.

Contact Us

Contact us today and we can work with you to identify the best setup for your application. Please provide the below information if you are uncertain of the specific cutter and holder you need:

Tip dresser type
Upper and lower cap profile (drawing or sample)
Gun profile (2D drawing or CAD file)
Weld material, cutter durability, and any other relevant information

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