Additive-Manufactured Abrasive Articles With Compacted Powder Layers
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Solution Overview
Problem
Existing abrasive articles formed via additive manufacturing are limited in size, quantity, and quality, particularly in creating large-scale, high-quality abrasive articles due to challenges in process variables such as powder composition, flowability, compaction force, and binder saturation, leading to issues with density and dimensional stability.
Innovation Solution
A method involving dry powder layering and binding techniques, using a bi-modal particle distribution of abrasive particles and binder materials, with controlled compaction and binder application to form abrasive articles, allowing for recycling of unused powder and optimizing surface texture and interfacial area ratios for improved performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional additive manufacturing methods are used to form abrasive articles, then the articles can be produced with controlled composition, but the articles are limited in size and quality due to issues with density and dimensional stability
Solution Approach 1:
The abrasive article is formed by depositing and compacting powder material in sequential layers, dividing the manufacturing process into discrete stages that build the article incrementally. This layered approach enables precise control over each layer's density and dimensions, which accumulates to produce large articles with overall dimensional stability.
Solution Approach 2:
The compaction density of the powder material is dynamically adjusted during the manufacturing process based on the layer position and article geometry. By varying compaction parameters (force, pressure, duration) for different layers, the process optimizes density distribution throughout the article, preventing dimensional instability while enabling large-scale production.
2Manufacturing precision
If high compaction force is applied to improve density, then the green body density improves, but the handling and processing difficulty increases
Solution Approach 1:
The compaction process applies force in periodic cycles corresponding to each layer deposition, rather than continuous high force. Each layer receives controlled compaction pulses that achieve sufficient density without excessive force, and the binder is applied periodically to progressively strengthen the green body for easier handling as manufacturing progresses.
Solution Approach 2:
A binder material is applied to the compacted layers during manufacturing to strengthen the green body structure before handling operations. This preliminary binding action prevents handling difficulties from arising, allowing high compaction forces to be used when needed without creating subsequent handling problems.
3Strength
If binder material is applied to bind powder particles, then the green body strength improves, but the powder flowability and compaction quality deteriorates
Solution Approach 1:
The manufacturing process separates binder application from compaction operations into distinct sequential steps. Powder material is first deposited and compacted to achieve optimal density and flow characteristics, then binder is applied in a separate stage to strengthen the green body. This segmentation prevents binder interference with compaction quality while still achieving necessary green body strength.
Solution Approach 2:
Compaction of the powder material is performed as a preliminary action before binder application. This ensures that the powder achieves optimal density and structural integrity through mechanical compaction alone, without the interfering effects of binder presence. The binder is then applied to provide additional strength for handling and subsequent processing.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables the production of large-scale, high-quality abrasive articles with enhanced surface texture and dimensional stability, facilitating improved material removal operations through controlled surface roughness and interfacial area ratios.
Implementation Method 1
a binder material is applied to bind the powder material
Implementation Method 2
moving a compaction object over the one or more layers of powder material to apply a force sufficient to compact the layer
Data Source
AI summary
A method for forming an abrasive article via an additive manufacturing technique including forming a layer of powder material comprising a precursor bond material and abrasive particles, compacting at least a portion of the layer to form a compacted layer, binding at least a portion of the compacted layer, and repeating the steps of forming, compacting, and binding to form a green body abrasive article.