Abrasive Tool and a Method for Finishing Complex Shapes in Workpieces

a technology of workpieces and tools, applied in the direction of gear teeth, gear teeth, gear surface conditioning devices, etc., can solve the problems of low work efficiency, low work efficiency, and low production efficiency of broaching tools

Inactive Publication Date: 2015-03-19
SAINT GOBAIN ABRASIVES INC +1
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

The method effectively forms complex shapes with surface roughness of less than 2 microns, achieving efficient material removal and extending tool life while maintaining accuracy and reducing operational costs compared to conventional methods.

Problems solved by technology

However, in the particular context of finishing workpieces to have complex shapes, few options are available since such finishing operations require exacting surface contours and tight dimensional tolerances.
However, broaching can be an expensive operation, due to high tooling costs, expensive machinery, set-up costs, tooling regrinding costs and slow material removal rates.
Milling processes are generally very slow, especially in machining difficult-to-machine materials, such as nickel alloys.
However, the Kuehne method may be used for external surfaces, and not internal surfaces, and thus is not applicable to the creation of internal slots.

Method used

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  • Abrasive Tool and a Method for Finishing Complex Shapes in Workpieces
  • Abrasive Tool and a Method for Finishing Complex Shapes in Workpieces
  • Abrasive Tool and a Method for Finishing Complex Shapes in Workpieces

Examples

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examples

[0070]A workpiece of Inconel 718 having dimensions of 2.85×2.00×1.50 inches was placed in a modified Cinternal ID / OD two-axis CNC grinder available from Heald Grinders.

[0071]A finishing operation was conducted on the workpiece using a vitrified CBN mounted point tool (B 120-2-B5-VCF10) from Saint-Gobain Corporation having a complex shape as illustrated in FIG. 4. The bonded abrasive body had a form depth (FD) of 0.8, a form ratio (FR) of 1.5, and an overhang ratio of 1.57. The tool had a form width of approximately 4.1 cm, an overhang length (OL) of 1.19 cm, a minimum diameter of 0.762 cm, and a maximum diameter of 3.76 cm.

[0072]The finishing process was conducted to simulate finishing of one 2 inch thick rotor with 60 slots to completion (equivalent to removing 1.2 inches of material from a 2 inch workpiece). During finishing, the depth of cut per pass was 0.0005″, such that the total depth of cut was a 0.010 inch on each side of a slot at a wheel speed of 40,000 rpm. Notably, the ...

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Abstract

An abrasive tool includes a bonded abrasive body having abrasive grains contained within a bonding material, wherein the bonded abrasive body comprises a complex shape having a form depth (FD) of at least about 0.3. The form depth is described by the equation [(R1−Rs) / R1], wherein Rs is a smallest radius (Rs) at a point along the longitudinal axis of the bonded abrasive body and R1 is a largest radius (R1) at a point along the longitudinal axis of the bonded abrasive body. The abrasive tool can be used to finish complex shapes in workpieces.

Description

CROSS-REFERENCE TO RELATED APPLICATION[0001]This application claims priority under 35 U.S.C. §120 to and is a divisional of U.S. application Ser. No. 13 / 198,916 entitled “Abrasive Tool and a Method For Finishing Complex Shapes in Workpieces,” by Besse et al., filed Aug. 5, 2011, which in turn claims priority under 35 U.S.C. §119(e) to U.S. Patent Application No. 61 / 371,581 entitled “Abrasive Tool and a Method For Finishing Complex Shapes in Workpieces,” by Besse et al., filed Aug. 6, 2010, both of which are assigned to the current assignee hereof and incorporated herein by reference in their entireties.BACKGROUND[0002]1. Field of the Disclosure[0003]The following is directed to abrasive tools and methods of finishing complex shapes in workpieces using such abrasive tools, and more particularly, use of bonded abrasive tools having particular shapes for finishing of complex shapes within workpieces.[0004]2. Description of the Related Art[0005]Within the industry of finishing, various ...

Claims

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Application Information

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Patent Type & AuthorityApplications(United States)
IPC IPC(8): B24B19/00B24D7/18
CPCB24D7/18B24B19/009B24B19/02B24B53/062B24D5/02B24D3/02B24D3/06B24B1/00
InventorBESSE, JOHN R.GRAHAM, DAVID C.SUBRAMANIAN, KRISHNAMOORTHYRAMANATH, SRINIVASANLAMOUREUX, MARC A.
OwnerSAINT GOBAIN ABRASIVES INC