MATERIAL PROCESSING DISC AND METHOD FOR ITS MANUFACTURE

Description

[0001] The invention relates to a material processing disc for processing material surfaces and a method for producing the material processing disc.

[0002] Material processing discs are known in practice, comprising a base body and an abrasive arranged on the base body. The base body has a central recess for direct or indirect connection to a drive shaft of a tool. With these material processing discs, the material surfaces of objects to be processed can be ground or polished. However, the removal rate of the known material processing discs is limited. Thus, coarse surface processing is not possible. Instead, a separate grinding disc is required, which is associated with high costs and additional effort.

[0003] JP H11 170176 A teaches a grinding tool comprising a drive shaft on which a disc-shaped grinding wheel for coarse grinding and a ring-shaped grinding wheel for fine grinding are mounted. The grinding wheel and the grinding wheel consist of grinding lamellae.

[0004] From document DE 198 12 515 A1, a flap grinding tool with a carrier body is known. Grinding flaps are arranged on the carrier body's circumference and end faces.

[0005] The invention is therefore based on the object of providing an alternative material processing disc which is suitable for both fine and coarse surface processing.

[0006] This object is achieved according to the invention by the material processing disc having the features of patent claim 1.

[0007] The material processing disc for processing material surfaces according to the invention comprises a base body with a central recess for connecting a drive shaft of a tool, an abrasive, and a grinding means. The abrasive means is arranged on the base body, and the grinding means surrounds the base body in a ring. The base body has a recess on its outer surface into which the grinding means engages. The grinding means has a circumferential projection on its inner surface that corresponds to the recess in the base body and extends radially inward.

[0008] This allows either the grinding tool or the abrasive to be brought into contact with the material surface by adjusting the grinding angle, i.e., the angle enclosed between the axis of the grinding tool and the material surface of the object to be machined. Furthermore, a firm connection between the base body and the grinding tool is ensured.

[0009] Thus, the material processing disc according to the invention enables both fine and coarse material processing without the need for an additional material processing disc. This reduces costs compared to the use of prior art material processing discs. The effort required for tool changes is eliminated.

[0010] In a preferred embodiment of the material processing disc according to the invention, the base body is a carrier plate made of plastic and / or comprising a mixture of resin and abrasive grain.

[0011] The roughing means of the material processing wheel according to the invention may have a convex outer surface, which improves the roughing performance of the roughing means.

[0012] The abrasive of the material processing disc according to the invention can be a flap disc, which is characterized by good grinding efficiency and a uniform grinding pattern. The abrasive can also comprise abrasive lamellae, which are bonded to the base body, in particular with an adhesive resin, thus ensuring secure fixation of the abrasive to the base body.

[0013] In an advantageous embodiment of the material processing disc according to the invention, the grinding agent comprises a mixture of resin and abrasive grain.

[0014] According to the invention, a method for producing a material processing disc with a grinding disc edge is proposed, the method comprising the following steps: a) Producing a base body and an annular grinding means surrounding the base body and b) gluing abrasive lamellae onto one grinding side of the base body.

[0015] The production of the base body and the roughing means enclosing the base body according to step (a) comprises the following steps: a.2.1) Providing two different mixtures of resin and abrasive grain, a.2.2) Introducing the mixtures into a production mold to form a first layer S 0 , wherein the production mold comprises an inner ring with an inner radius ri , an outer ring, and a disk-shaped base surface connecting the inner ring and the outer ring, wherein the first mixture forming the base body is applied to an inner ring surface with the inner radius ri and an outer radius rm,n so that a first base body layer is formed, and the second mixture forming the roughing agent is applied adjacent to the first base body layer on an outer ring surface of the base body layer adjacent to the inner ring surface, which outer ring surface has the inner radius rm,n and extends to the outer ring of the production mold so that a first roughing agent layer is formed, a.2.3) applying n further layers S n on the first layer S 0 according to step (a.2.2) to form an (n+1)-layer stack, where n is a natural number, and a.2.4) compacting the (n+1)-layer stack in a press such that the n base body layers form the base body and the n roughing agent layers form the roughing agent.

[0016] In step (a.2.3), at least two layers S 1 , S 2 are applied to the first layer S 0 according to step (a.2.2), so that a stack of at least three layers is formed. Thus, by appropriately designing the radii rm,n of the individual layers S 0 to S 2 , a recess in the base body and a projection of the roughing means corresponding to the recess of the base body can be realized, so that the roughing means is connected to the base body.

[0017] In steps (a.2.2) and (a.2.3), layers S 0 and S 0+u are applied, each having the radius rm,n, wherein the radius rm,n of the layer S 0 to S 0+u and of the layers S no to S n is greater than the radius rm,n of the layers S 0+u+1 to S n-0-1 and n - u - o ≥ 1, so that a recess is formed on the base body and a projection is formed on the roughing means.

[0018] The roughing agent may be manufactured in step (a) to include a concave outer surface, thereby improving the roughing performance.

[0019] In step (b), the abrasive lamellae are glued or fixed to the grinding side of the base body, for example with an adhesive resin, whereby adhesive resins have particularly good adhesive properties.

[0020] Further advantages and advantageous embodiments of the subject matter of the invention can be found in the description, the drawings and the patent claims.

[0021] An embodiment of a material removal disc according to the invention is shown schematically in the drawing and is explained in more detail in the following description. It shows: Fig. 1 is a plan view of a material processing disc according to the invention; and Fig. 2 is a section through the material processing disc according to Figure 1 along line II-II together with an object to be processed.

[0022] Fig. 1 shows a material processing disc 10 according to the invention with a base body 20, an abrasive 30 and a roughing means 40.

[0023] The base body 20 is disc-shaped and has a central recess 21 with a radius ri for connecting a drive shaft of a tool. The roughing means 40 encloses the base body 20 in a ring shape, wherein a lateral surface 22 of the base body 20 is in contact with an inner surface 41 of the roughing means 40. A recess 23 is formed on the lateral surface 22 of the base body 20 and extends along the circumferential side. The roughing means 40 comprises, on an inner surface 41, a projection 42 corresponding to the recess 23 of the base body 20 and has a convex outer surface 43 with respect to an object 50 to be machined, i.e., in cross-section, the outer surface 43 of the roughing means 40 is curved outwards.

[0024] The base body 20 and the grinding means 40 surrounding the base body 20 can comprise (n+1) layers S 0 to S n . The (n+1) layers S 0 to S n each comprise a disc-shaped base body layer and a disc-shaped grinding means layer, each formed from a mixture of resin and abrasive grain. The base body layers each have an inner radius ri , which corresponds to the radius of the recess 21 of the base body, and an outer radius rm,n . An inner radius rm,n of the grinding means layer corresponds to the outer radius rm,n of the base body layer.

[0025] In the layer or layers S 0+u+1 to S no-1 , which are located in the axial direction at the level of the recess 23 of the base body 20 and the projection 42 of the roughing means 40, the outer radius of the corresponding base body layer(s) or the inner radius of the corresponding roughing means layer(s) rm , 0+u+1 to no-1 is smaller than the outer radius of the base body layer(s) or the inner radius of the roughing means layer(s) rm , 0 to 0+u and no to n of the layers S 0 to S 0+u and S no to S n .

[0026] Alternatively, the base body can be made of a suitable plastic.

[0027] An abrasive 30 is arranged on a side of the base body 20 facing the object 50 to be machined, or the grinding side 24. The abrasive 30 comprises abrasive lamellae 31, which are bonded to the grinding side 24 of the base body 20 with an adhesive resin.

[0028] How Figure 2shows, the material processing disk 10 has a rotation axis 11. The rotation axis 11 encloses an angle SW together with a plane 52 which corresponds to the extension of the surface 51 of the object 50 to be machined.

[0029] By adjusting the angle SW, a surface of the grinding wheel 10 in contact with the surface 51 of the object 50 to be machined can be changed. With a small or obtuse angle SW, the surface 51 can be machined with the grinding means 40. If the angle SW is large, in particular close to or equal to 90 degrees, the surface 51 to be machined is in contact with the grinding means 30. List of reference symbols

[0030] 10Material processing wheel 11Axis of rotation 20Base body 21Recess 22Side surface 23Recess 30Abrasive 31Abrasive lamella 40Grinding agent 41Inner surface 42Protrusion 43Outer surface 50Object 51Surface SWAngle ri Inner radius rm, 0+u+1 to no-1 Outer radius of the base body layer or inner radius of the roughing middle layer of the layer(s) S 0+u+1 to S no-1 , where n, o, u are natural numbers and n is greater than or equal to one. rm, 0 to 0+u and no to n Outer radius of the base body layer or inner radius of the roughing middle layer of the layer(s) S 0 to 0+u and S no to n , where n, o, u are natural numbers and n is greater than or equal to one.

Claims

1. A material processing disk for processing material surfaces, the material processing disk comprising a base body (20) having a central recess (21) for being attached to a drive shaft of a tool, a grinding unit (30) being disposed on the base body (20) and a scrubbing unit (40) annularly encircling the base body (20), the base body (20) comprising a recess (23) on its jacket surface (22), the scrubbing unit (40) engaging in the recess (23), and the scrubbing unit (40) comprising a circumferential collar (42) on the inner surface (41), the collar (42) corresponding to the recess (23) of the base body (20) and extending inwards in the radial direction.

2. The material processing disk according to claim 1, wherein the base body (20) is a support plate which is made of plastic and / or comprises a mixture of resin and abrasive grain.

3. The material processing disk according to claim 1 or 2, wherein the scrubbing unit (40) has a convex outer surface (43).

4. The material processing disk according to any one of the claims 1 to 3, wherein the scrubbing unit (30) is a flapped disk.

5. The material processing disk according to any one of the claims 1 to 4, wherein the grinding unit (30) comprises grinding-unit lamellae (31), which are glued on the base body (20) using an adhesive resin.

6. The material processing disk according to any one of the claims 1 to 5, wherein the scrubbing unit (40) comprises a mixture of resin and abrasive grain.

7. A method for producing a material processing disk (1), the method comprising the steps of a) producing a base body (20) and an annular scrubbing unit (40) encircling the base body (20) and b) gluing grinding-unit lamellae (31) on a grinding side (24) of the base body (20), wherein the production of the base body (20) and the scrubbing unit (40) encircling the base body (20) comprises the following steps in accordance with step a): a.2.1) providing two different mixtures of resin and abrasive grain. a.2.2) introducing the mixtures in a production mold for forming a first layer S0, the production mold comprising an inner ring having an inner radius ri, an outer ring and a disk-shaped base surface connecting the inner ring and the outer ring, the first mixture forming the base body (20) being applied on an inner ring surface having the inner radius ri and an outer radius rm,n so that a first base-body layer is formed, and the second mixture, which forms the scrubbing unit (40), being applied on an outer ring surface of the base-body layer adjacent to the first base-body layer, the outer ring surface being adjacent to the inner ring surface and having the inner radius rm,n and extending to the outer ring of the production mold so that a first scrubbing-unit layer is formed. a.2.3) applying n further layers Sn on the first layer S0 according to step a.2.2) for forming a (n+1)-layered stack, n being a natural number. a.2.4) compacting the (n+1)-layered stack in a press so that the n base-body layers form the base body and the n scrubbing-unit layers form the scrubbing unit (40). wherein in step a.2.3), at least two layers S1, S2 are applied on the first layer S0 in accordance with step a.2.2) so that an at least triple-layered stack is formed; and wherein in steps a.2.2) and a.2.3), layers S0 or S0+u are applied which each have a radius rm,n, radius rm,n of layer S0 to So+u and layers Sn-o to Sn being larger than radius rm,n of layers S0+u+1 to Sn-o-1 and n-u-o ≥ 1.

8. The method according to claim 7, wherein the scrubbing unit (40) is produced in such a manner in step a) that it comprises a concave surface (43).

9. The method according to any one of the claims 7 to 8, wherein the grinding-unit lamellae (31) are glued to the grinding side (24) of the base body (20) in step b) using an adhesive resin.