Method of manufacturing and article for cutters for pdc cutting systems

Abstract

Articles providing one or more alignment features for controlling orientation of abrasive elements and articles providing destructive interference and durability of abrasive elements during operation can be utilized to enhance material removal systems including milling drums and drumless milling products, systems for removing materials such as concrete or asphalt or industrial flow applications, articles and methods. Articles and methods of manufacturing the articles are provided. The methods allow for easy configuration of matching pairs of individual abrasive elements according to a variety of applications in a parametric, semi-parametric or non-parametric manner and can provide one or more alignment features for controlling orientation of the abrasive elements and sinusoidal, near-sinusoidal or non-sinusoidal destructive interference effects while providing durability of the abrasive elements during operation.

Description

[0001] Cross-references to related applications

[0002] This application claims the benefit and / or priority of U.S. Provisional Patent Application Serial No. 62 / 965,591, entitled “CUTTER FOR PDC CUTTING SYSTEM,” filed January 24, 2020, and U.S. Provisional Patent Application Serial No. 62 / 965,529, entitled “ALIGNMENTFEATURE,” filed January 24, 2020. The entire contents of the above applications are incorporated herein by reference. Technical Field

[0003] The disclosed innovation relates to articles for material removal purposes and methods for manufacturing articles. More specifically, this innovation relates to a product that can be used in systems for preparing surfaces or removing materials (such as, for example, concrete, asphalt, resin, etc.) from surfaces, for example, in connection with the removal and / or placement or replacement of street pavement signs, traffic signs, wiring, signals, wires (such as embedded communication lines), etc. As well, it can remove resin or any other type of flooring material from surfaces such as industrial floors. The disclosed method allows for the advantageous manufacture and construction of articles. Background Technology

[0004] A characteristic of conventional and recent advances in the art lies in milling drum and drumless milling operations for material removal. In such operations, the system can employ a variety of impact tools. These tools, known in the art, can have permanent or replaceable designs and can be incorporated into a pick or plate or directly attached to the drum. It should be understood that replaceable designs can be configured (in a permanent or replaceable manner) to a sub-assembly of a retainer or impact tool, and such retainer is attached to the pick or plate. It should also be understood that the prior art includes pre-manufactured round and flat objects of such impact tools. Such tools can be made from carbide compositions, sintered diamond compositions, etc. In other words, the grinding section can include virtually any material conventional in the art, such as, but not limited to, polycrystalline diamond (PCD) materials. It should be understood that the conventional use of these tools does not concern the orientation of the tool on the pick or plate or drum, but may concern the placement of the pick relative to the drum centerline (if any). Summary of the Invention

[0005] The following is an overview of the invention to provide a basic understanding of some aspects of it. This overview is not a comprehensive summary of the invention. It is not intended to identify important / key elements of the invention or to describe its scope. Its sole purpose is to present some concepts of the invention in a simplified form as a prelude to the more detailed description that follows.

[0006] The present invention disclosed and claimed herein includes, in its various aspects, articles and methods comprising configurations that may include abrasive elements for a material removal system. It should be understood that almost all systems are characterized by a rotational motion that engages multiple abrasive elements with the surface being processed. A contact area, referred to as a working area, can be characterized as the portion of the material being removed and the material removal system in contact with the material being removed. Multiple abrasive elements may be permanently or removably attached to the material removal system, and said multiple abrasive elements may be attached such that the rotational motion of the system moves the abrasive portion into contact with the material to be processed and provides a working area, which removes material from the location of said area. Multiple working areas may exist in different embodiments.

[0007] This innovation offers advantages that allow for finer control over the abrasive removal of material within the working area, thereby providing superior surface conditions. Control can arise from aspects of this innovation, such as, for example, orientation control features, destructive interference effect features, or combinations thereof. Aspects of this innovation include manufacturing methods that can form a set of parametric or nonparametric parameters that, when used as disclosed, exhibit destructive interference effects and alternatively or in combination form orientation control features. It should be understood that orientation control features provide advantages for sinusoidal and other configurations of the working edge design, which can contribute to providing superior surface conditions.

[0008] To achieve the foregoing and related objectives, certain illustrative aspects of the present invention have been described herein in conjunction with the following description and accompanying drawings. However, these aspects indicate only a few of the various ways in which the principles of the present invention can be employed, and the present invention is intended to include all such aspects and their equivalents. Other advantages and novel features of the present invention will become apparent to those skilled in the art by considering the following detailed description of the present invention in conjunction with the accompanying drawings, and the present invention is intended to be constructed to include all such variations and modifications, provided they fall within the scope of the appended claims or their equivalents. Attached Figure Description

[0009] This innovation can take physical form in certain components and their arrangements, and various implementation schemes will be described in detail and illustrated in the accompanying drawings:

[0010] Figure 1A This presents a concept of a rotating plane based on one aspect of this innovation.

[0011] Figure 1B An isometric view of a component from one aspect of this innovation is presented.

[0012] Figures 2A to 2H A view of a grinding element that does not require orientation control is presented.

[0013] Figures 3A to 3DA view of an alternative grinding element that does not require orientation control is presented.

[0014] Figures 4A to 4F A view of a grinding element without orientation control is presented.

[0015] Figures 5A to 5D This presents aspects of the innovation to a certain extent as related to Figures 4A to 4F Side view, front view and isometric view of grinding elements similar to those of the component.

[0016] Figures 6A to 6C An exemplary sinusoidal profile of an article of manufacture according to aspects of this innovation is provided.

[0017] Figures 7A to 7D Side view, front view and isometric view of the grinding element according to various aspects of this innovation are presented.

[0018] Figures 8A to 8D Side view, front view and isometric view of the grinding element according to various aspects of this innovation are presented.

[0019] Figures 9A to 9D Exemplary paired front and side views of corresponding contours manufactured by blank grinding elements according to various aspects of this invention are presented.

[0020] Figures 10A to 10D Side view, front view and isometric view of a grinding element according to an aspect of the present invention are presented, which present features in alternative embodiments illustrating selected aspects of the present invention. Detailed Implementation

[0021] This invention will now be described with reference to the accompanying drawings, wherein similar reference numerals are used throughout to denote similar elements. In the following description, numerous specific details are set forth for illustrative purposes in order to provide a thorough understanding of the invention. However, it may be apparent that the invention can be practiced without these specific details. In other cases, structures and devices may be shown in block diagram form to facilitate the description of the invention.

[0022] Although specific characteristics (e.g., thickness, orientation, configuration, etc.) are described herein, it should be understood that the features, functions, and benefits of this invention may be derived from characteristics different from those described herein. These alternatives will be included within the scope of this invention and the appended claims.

[0023] For embodiments as shown in the figures, the article may include a predetermined combination of a retainer and multiple impact force devices. The article may also be a constructed impact force device, and it should be understood that the meaning should be clearly derived from the context of use. It should also be understood that this innovation may be provided in embodiments where the impact force device can be permanently mounted to other elements of the material removal system, and in embodiments where the mounting can be considered replaceable at one or more different levels. In other words, it should be understood that the abrasive element may advantageously be a removable or non-removable abrasive element (removable from or not removable from the assembly, or removable from or not removable from a removable retainer, wherein the retainer and the abrasive element are considered as abrasive devices).

[0024] Turn now Figure 1A The illustration depicts an exemplary embodiment relating to one aspect of the present invention, characterized by the presentation of a rotated 'plane' or slice or portion of a segment affected by a material removal operation. This plane can be considered as an effective working area with a specified thickness, and in one embodiment, multiple matching profiles from a set of profiles according to an aspect of the present invention are provided, as will be discussed herein. Figure 1A A rollerless milling apparatus comprising multiple blade segments is presented. It should be understood that conventional milling cylinders equipped according to this disclosure can also present a plane of rotation as discussed herein.

[0025] It should be understood that the power of the material removal system is almost always transferred from the material removal device to the material being processed through rotation about the main axis of the material removal system (which should be understood to be parallel to the X-axis, as shown in the figure). A slice or segment of the system perpendicular to the axis can be considered as a plane of rotation (e.g., a plane formed by the two dimensions of the Y and Z axes). In this context, the plane of rotation may not be a true plane, as it is considered to have a thickness 102. The thickness 102 can be considered as a specific set of abrasive elements 104S (e.g., ...). Figure 1B The width of the material removal area (shown) is given, wherein each of the groups has a plurality of abrasive elements 104N and 104N+1 along substantially the same plane of rotation. It should be understood that the width of the working area formed by abrasive element 104N and the width of the working area formed by abrasive element 104N+1 may not be equal, and the thickness 102 is the cumulative thickness of the material processed by the sequential abrasive elements 104N, 104N+1 in the group 104S.

[0026] The total working area 106 can be as shown in the figure. In this example, the total working area may include an overlap between an adjacent thickness 102 of one rotating plane and the next rotating plane. In other embodiments, the total working area may be configured to have or not have such an overlap. In still other embodiments, the total working area may have multiple working areas spaced apart by a predetermined interval. It should be understood that, in embodiments, the width of the group 104S may overlap or span one or more adjacent or intermittent segments, thereby providing a constructible pattern across the total working area 106. In still other embodiments, multiple working areas may appear at different radial distances from the main rotation axis, thereby allowing for the removal of material to a depth greater than one.

[0027] It should be understood that, although not shown, embodiments may include several alternative material work area configurations. For example, when setting up a controlled work surface that includes deeper recesses for laying wires, signs, road reflectors, or other surface features, various radial dimensions may be selected for such applications. In one embodiment, a 0.25-inch (or as needed) central recess may be provided beneath the entire work surface. Another example could be the variable surface depth result for reflective inlays in the prepared road surface.

[0028] Figure 1B An isometric view of component 100, representing one aspect of this innovation, is presented. It should be understood that... Figure 1B Depicting and will be discussed in this article Figures 6A to 8D Similar embodiments of the replaceable apparatus are discussed in connection with this. In the context of the illustrated rollerless material removal system, the abrasive elements are permanently attached to the respective blades constituting the rollerless material removal system. It should be understood that in this embodiment, another aspect of the invention, namely (as will be discussed herein) alignment control, can be set not only for the radial plane of a single blade (which has continuous abrasive elements 104N and 104N+1), but also across the span of the main axis of the material removal system (e.g., along such...). Figure 1A As shown in 106), the action extends from one blade to the next.

[0029] exist Figure 1BIn the illustrated embodiments, the polished portion attached to the shoulder is shown centered along the thickness dimension of the blade element. Although not shown, this centering indicates only one set of embodiments, and other embodiments may provide polished portions offset from the blade centerline in any direction from the centerline of the thickness dimension. In other words, while the polished section is illustrated as symmetrical to the blade element body, it may be asymmetrically (not shown) offset to the left, right, or both left and right of the blade element centerline. For example, in one embodiment, the polished section may be offset beyond the side edge of the blade core to create a side clearance. In other embodiments, the disclosed innovation can be configured with polished sections of blade elements having different offsets, and even polished sections of individual blade elements may have sections with different offsets along the periphery of the blade element. Aspects of this innovation can provide orientation control to facilitate these embodiments, as discussed herein.

[0030] Turn now Figures 2A to 2H The illustration shows a view of multiple grinding elements 202 in the form of blank circular objects, for which no orientation control is required. It should be understood that in these examples, the multiple blank circular objects may be permanently attached to the retainer 204, and the combination of the retainer 204 and the multiple circular objects 202 can be used as a replaceable grinding tool. As shown in this embodiment, the two versions 200A and 200B illustrated constitute a group that can be used as a group such as 104S disclosed herein.

[0031] The grinding apparatus may be shown as including a retainer portion 204 and a plurality of grinding portions 202. The retainer portion 204 may also be configured to receive a plurality of permanently mounted grinding portions 202. The retainer portion 204 may have a tongue (or key) 206 that adapts to a corresponding groove in a shoulder portion of a mating blade element (not shown). The retainer portion may also have an attachment mechanism 208, such as a hole for a screw, bolt, etc. (not shown). The permanently mounted grinding portions 202 may have various shapes, such as circular, rectangular, etc. (as shown in various figures and discussed herein), and compositions such as polycrystalline diamond (PCD) and the attachment of the grinding portions may be based on any method of geometry known in the art. Although those skilled in the art may know how to attach the grinding portions 202 to the retainer 204, the disclosed innovations include aspects that have been found to provide advantages over methods known in the art. For example, the grinding portions 202 may be attached from a top plane with a sweep angle 210. It should be understood that this angle 210 can be selected at least based on the specified end use of various designs or the intended application associated with various surface materials to be processed and removed. For non-limiting examples, angle 210 can be in the range of 0 to 45 degrees relative to a horizontal plane, or more particularly in the range of 10 to 30 degrees. It should be understood that angle 210 can form a rotation axis Z for a plurality of circular objects 202. It should also be understood that in this configuration shown, orientation control of the plurality of circular objects 202 regarding rotation about axis Z is not required (unlike other embodiments that highlight the aspect of orientation control in this invention, as discussed later). Additional examples include chamfering the grinding portion 202 at each corner of its leading edge and from the edge of the inclined plane toward the three vertical edges. It should be understood that the chamfering and other designs of the grinding portion 202 are considered to be within the scope of this invention.

[0032] Turning Figures 3A to 3D This provides another example of a polishing element 302 that does not require orientation control. In this example, with regard to... Figures 2A to 2H Compared to the previous discussion, the grinding element 302 is depicted as a strip shape without a rotation axis Z.

[0033] Turn now Figures 4A to 4F An exemplary combination of multiple grinding elements 402 and a retainer 204 is depicted. It should be understood that in this embodiment, the grinding circle has been modified to provide a truncated circle having a face 412 at its junction with the material to be processed in the material removal zone. In this example, it should be understood that... Figures 4A to 4FConversely, as not shown, orientation control can provide advantages over components without orientation control. For example, placing and permanently attaching multiple truncated circular objects 402 into a retainer 204 can make it difficult to control rotation about axis Z in any direction. Since the grinding element is no longer circular as a whole, rotation encountered when mounting the truncated circular objects may cause multiple faces 412 to no longer align at the sharp working edges (because such alignment would be inconsistent with an aspect of the present invention as discussed herein). For example, truncated circular object 402A may rotate clockwise, while truncated circular object 402B may rotate counterclockwise, and then the working edges may present as angled lines. This may be particularly important in applications where material removal systems (e.g., such as...) Figure 1A and Figure 1B In the controlled radial action plane of the appliance (as shown), the first profile is followed by the second profile.

[0034] In an embodiment characterized by a truncated circular grinding element, Figures 5A to 5D Presented aspects related to this innovation Figures 4A to 4F The components are similar, but differ in that the grinding element provides an alignment feature 514 in the side, front, and isometric views. In these figures, the alignment feature 514, which provides a saddle-shaped locator, is shown. It should be understood that a matching feature on a retainer (such as, for example, retainer 204) or on a permanent placement device (such as, for example, on a roller or plate, or on a blade in rollerless applications) can provide a feature opposite to the alignment feature 514 (not shown). The alignment feature 514 is then used to prevent or reduce unwanted rotation when assembling the grinding instrument or permanently attaching the abrasive to a material removal system component. Because the alignment feature 514 provides a predetermined settling point, rotation about a centerline passing through an approximate radius of the grinding element is prevented, and alignment of the working edges is more easily maintained. It should be understood that while the illustrated embodiment depicts the alignment feature 514 as a continuous radial feature (as is made easier to manufacture and discussed herein), other configurations are also considered to fall within the scope of this invention. For example, triangular or serrated features (not shown) can provide more controlled alignment or multiple constructible positions, as such embodiments may be desired. It should be understood that the triangular feature can provide rounded tips and gaps in the mating feature to facilitate manufacturing and assembly.

[0035] Turning Figures 6A to 6CThe exemplary sinusoidal profile of the article is presented. The periphery of the plurality of grinding elements 104 (represented by both 104N and 104N+1, denoted as 104S) occupying the working area can be sinusoidal or near-sinusoidal. It has been found that, for some embodiments, it is preferred to have a sinusoidal or near-sinusoidal shape at this periphery, as this provides a durable striking surface (with minimal stress concentration) while providing a height-controlled overlap from the first profile (such as 104N) to the second profile (such as 104N+1), thereby functioning in rotational motion through a plane of rotation (such as 102), as previously discussed. It should be understood that an embodiment according to the present invention may be characterized by: a set of peripheral shapes that are non-sinusoidal but still form a destructive interference pattern (not shown) when applied as disclosed.

[0036] It has been determined that providing destructive interference implementation schemes can be advantageous for material removal when designed to achieve finer surface finishes. For example, in Figures 6A to 6C As disclosed in the embodiments, for certain materials (such as, but not limited to, flooring material, asphalt, or concrete), an improvement in overall material removal efficiency can be achieved because each peak removes a substantial portion of the material being processed during the passage of the first contour (e.g., 104N) of the article engaging with the surface being processed, while subsequent abrasives (e.g., 104N+1) are used to remove the weakened middle portion of the processed material from the surface being processed. It has been advantageously found that the sinusoidal shape provides the durability and strength of a near-circular abrasive element combined with the cutting / grinding coverage area of ​​a larger rectangular abrasive element. This has already shown benefits, for example, in concrete removal applications.

[0037] Figure 6A A view of a grinding element according to one aspect of this invention is provided. Articles of an grinding element having a sinusoidal peripheral shape, such as in 104N, and articles of an grinding element having a sinusoidal peripheral shape, such as in 104N+1, are shown. It should be understood that the two profiles are complementary to each other, as each profile has similar amplitudes in its sinusoidal shape but is 180 degrees out of phase (thus providing destructive interference).

[0038] In the implementation, N can be an integer and can represent the number of peaks in the first profile. In the illustrated implementation, N = 4. In this example, it should be understood that 104N+1 will then have five peaks. The thickness 102 can be considered as peaks extending slightly outward beyond 104N+1. Figure 6B A slightly angled view of the two elements, 104N and 104N+1, is provided because this view better illustrates their effect when used as 104S. This view indicates the destructive interference of sinusoidal patterns with a 180-degree phase difference.

[0039] It should be understood that the destructive interference pattern method can be controlled by selecting the "N" and amplitude of the sinusoidal effect so that the surface of the processed material allows the remaining ridge height and spacing to be controlled to almost any desired ridge height and number. Figure 6C The illustration shows a specific exemplary implementation in which the selection of “N” and amplitude can provide a 0.06 crest-to-trough lateral dimension (across the working edge) while maintaining a ridge height of 0.009 depth dimension.

[0040] While it should be understood that the term "pair" is used for ease of discussion, the implementation of paired grinding elements is not strictly constrained to an even number of grinding elements in the plane of rotation. Rather, the sinusoidal offset can simply be from one working grinding element to the next in a particular plane of rotation. In other words, the number of working grinding elements in the plane of rotation can be odd, not even, as long as at least two sequential working grinding elements in a row are complementary.

[0041] Figures 7A to 7D and Figures 8A to 8D Side views, front views, and isometric views of grinding elements (such as 104N and 104N+1) according to aspects of this invention are provided. In these exemplary embodiments, the working edges of the grinding elements 104N and 104N+1 are depicted as sinusoidal curves, wherein... Figures 8A to 8D The sine curve has the same properties as Figures 7A to 7D The amplitudes are similar to those of a sinusoidal curve, but the phases differ by 180 degrees. This feature provides additional advantages, such as, for example, ease of manufacturing matching pairs of appliances from raw materials of a single circular object, as discussed herein. It should be understood that, in this embodiment, the alignment feature 714 provides alignment control and ensures destructive interference patterns, such as, for example, 104N and 104N+1, at the sinusoidal working edges.

[0042] Turn now Figures 9A to 9D An exemplary front view and side view of an article of a pair of grinding elements are provided. Figures 9A to 9B An implementation is provided, characterized by: setting the size parameters, which allows for the machining (as is known in the art) of a single circular object according to the matching of the sine wave peaks and amplitudes from saddle point positioning features C, F, KK, and QQ (e.g.) to A and AA, utilizing the additional efficiency and control of various aspects of the present invention. It should be understood that UU can be dimensionally independent of other parameters. It should also be understood that some implementations can provide aspects of the present invention that can be obtained without setting the size parameters. Figures 9C to 9DImplementations with actual workpiece dimensions are provided. In these figures, pairs of complementary grinding elements (e.g., sequential grinding elements 104N and 104N+1, as previously discussed) can be manufactured from blank grinding elements according to aspects of this invention. Exemplary views show that the pairs have similar sinusoidal designs but are 180 degrees out of phase. It should be understood that conventional grinding elements can be supplied starting with a single conventional blank (e.g., radius R, or other examples such as E, H, G, EE, or RR) with a circular profile. Dimensions are provided in letter form, which can be generated as needed taking into account known manufacturing techniques, but in some implementations can be parametrically correlated with each other. Parametric correlation can, for example, provide efficiency in machining operations and reduce stress concentrations in the finished product. Parametric correlation can also provide scalability across different starting points of the blank circularity. It should be understood that the number of peaks for each sine wave can be selected based on the material to be processed (i.e., the number of peaks can be selected for a particular end application), because different material applications can provide different desired levels of abrasive element stability, and fewer peaks can provide a trade-off between deeper engagement and durability, while more peaks can provide a finer finish and a material removal rate. In this implementation, therefore, different dimensions can be desired based on many different factors. In other implementations (e.g., those where parameter size settings can be selected), dimensions can be expected to be related to each other. Therefore, in this implementation, dimensions can be selected such that each dimension can be a predetermined amount, which can be parameterically set as a ratio to an initial size (such as, for example, the initial size of the radius of a conventional abrasive circular element). In this way, the article of a pair of abrasive elements can be represented by a parametric constant, and scalability can be achieved across different conventional starting blanks. As noted, Figures 9C to 9D An exemplary implementation is provided where a particular size has been selected as an exemplary choice for a particular application.

[0043] A manufacturing method may be illustrated as follows. For the desired end application, parametric constants can be determined. For the desired end application, a first number "N" of the peaks of a selected sine pattern and the selection of its amplitude can be determined. A starting blank circle can then be selected, and processing of the circle can begin according to the selected properties and parametric constants, thereby producing a set such as 104S providing destructive interference, for example. It should be understood that the processing may include parametric or non-parametric processing of the alignment features. In other words, the alignment features can be sized and selected parametrically or otherwise (e.g., the alignment features can be sized and selected based on standard mounting sizes, regardless of the diameter of the selected blank circle). It should also be understood that, for the desired end application, one or more processing of the selected selections of "N", amplitude, sine pattern, and alignment features (or selected properties) can be performed non-parametrically.

[0044] Figures 10A to 10D Side, front, and isometric views of a grinding element 1002 according to one embodiment highlighting a particular aspect of the invention are provided. In this exemplary embodiment, the working edge is shown as a dashed line. This example conveys an aspect of the invention that allows for the provision of an alignment feature 514 regardless of the contour of the grinding element 1002 (or generally, virtually any grinding surface) in the working area. (See also: Regarding...) Figures 4A to 9D The alignment feature discussed can provide benefits regardless of many other options in the configuration of the working edge. It should be understood that working impact elements may include aspects that do not require the use of alignment feature 514 (or 714), as described herein. Figures 3A to 4D The innovation of having alignment feature 514 (or 714) is disclosed, but can be obtained with or without setting the parameter size of the sinusoidal effect, and can be presented as a truncated circular object (as per [the description of the invention]). Figures 5A to 5D The discussion (here, 514)).

[0045] While the embodiments of the present invention illustrated and described herein have been emphasized, it should be understood that other embodiments and their equivalents may be implemented and many changes may be made without departing from the principles of the present invention. Furthermore, the foregoing embodiments may be combined to form further embodiments of the disclosed invention. Therefore, it should be clearly understood that the foregoing descriptive matters are to be interpreted merely as illustrative examples of the present invention and not as limitations. It will be apparent to those skilled in the art that various changes and modifications may be made without departing from the scope of the invention as defined in the claims. Moreover, with regard to the term "includes" as used in the detailed description or claims, such a term is intended to be inclusive in a manner similar to that of the term "comprising" when it is interpreted as a transitional term in the claims.

Claims

1. A method for manufacturing a plurality of material removal elements for a material removal system, comprising: Disassemble the main circular material removal element to form a pair of striking force instruments, wherein the first instrument in the pair has a first profile shape and the second instrument in the pair has a second profile shape; For the first contour shape and the second contour shape, for a corresponding portion of each contour shape, at least one of a sine pattern and a truncated circular pattern is selected, and Regarding the selection of the sine pattern: A first number "N" of peaks is selected for the first contour shape, which determines that the number of peaks for the second contour shape is the first number plus one; Select the amplitude of the sine pattern; When the matching pair is installed as a group of material to be removed in the material removal system, the corresponding portion of the second profile shape follows the corresponding portion of the first profile shape in the rotation path, and the matching pair forms a destructive interference pattern when applied to the material being processed for the material removal application. Regarding the selection of the truncated circular pattern: Alignment features are provided on each of the first and second devices at locations other than the respective portions of each contour shape of the corresponding first and second devices; The alignment feature prevents the first and second instruments from rotating relative to each other when each instrument is attached to the material removal system.

2. The method of claim 1, wherein the dimensions of the first and second apparatus are based on predetermined parameter constants for the selection of the sinusoidal pattern.

3. The method of claim 1, wherein the dimensions of the first and second devices are based on a predetermined semi-parametric constant for the selection of the sinusoidal pattern.

4. The method of claim 1, wherein the dimensions of the first and second appliances are based on predetermined parameter constants for the selection of the truncated circular pattern.

5. The method of claim 1, wherein the dimensions of the first and second instruments are based on a predetermined semi-parametric constant for the selection of the truncated circular pattern.

6. The method of claim 1, wherein the alignment feature comprises a saddle-shaped, triangular, or serrated configuration.

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