3D Printed Refiner Segment Patterns
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Solution Overview
Problem
The manufacturing process of refiner discs is complex, time-consuming, and expensive, limiting the creation of effective segment patterns due to mechanical machining with coarse cutting tools, which results in high replacement costs and suboptimal fiber quality.
Innovation Solution
A method utilizing 3D printing to produce refiner segments, where a CAD-generated model is printed and used to create a mold for casting, allowing for more complex and efficient surface structures without the limitations of traditional machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional mechanical machining with coarse cutting tools is used to manufacture refiner segments, then the manufacturing process is simpler and more accessible, but the manufacturing precision and complexity of segment patterns are limited
Solution Approach 1:
The patent replaces traditional mechanical machining with 3D printing technology to manufacture refiner segments. This substitution enables the creation of complex segment patterns with high precision that were previously unattainable through conventional cutting tools, while the digital nature of 3D printing simplifies the overall manufacturing process by eliminating complex toolpath programming and multiple machining operations.
Solution Approach 2:
The invention changes the fundamental manufacturing parameter from subtractive mechanical machining to additive 3D printing. This parameter change allows for the direct fabrication of complex geometries and fine surface structures that define effective segment patterns, significantly improving manufacturing precision without proportionally increasing process complexity.
2Productivity
If traditional mechanical machining is used to create refiner segments, then the equipment and process are simpler, but the production time is longer and productivity is lower
Solution Approach 1:
By substituting traditional mechanical machining with 3D printing, the patent achieves faster production times for complex segment patterns. The additive process can fabricate intricate geometries in a single continuous operation, whereas conventional machining would require multiple setup changes, tool changes, and sequential operations, thereby improving productivity and reducing manufacturing time.
3Reliability
If complex segment patterns are attempted with traditional machining, then fiber quality may improve, but the manufacturing cost increases due to time and material waste
Solution Approach 1:
The patent replaces traditional machining with 3D printing to manufacture refiner segments with complex patterns. This substitution reduces manufacturing costs by minimizing material waste (additive vs. subtractive manufacturing), reducing production time, and enabling the creation of optimized segment patterns that improve fiber quality without proportionally increasing manufacturing complexity or cost.
Solution Approach 2:
By changing the manufacturing parameter from subtractive machining to additive 3D printing, the invention achieves cost-effective production of complex segment patterns. The additive process builds material only where needed, significantly reducing waste compared to machining, while the digital workflow reduces setup and programming costs, making complex patterns economically viable.
Data Source
AI summary
A disc-type refiner segment and a production method thereof are provided for refining lignocellulosic material, comprising providing production data of the disc-type refiner segment;supplying the production data to a 3D printer; 3D printing a pattern of the disc-type refiner segment; using the pattern of the disc-type refiner segment to generate a mold of the of the disc-type refiner segment; and molding or casting the disc-type refiner segment using the mold.