Abrasive Tool Blade Teeth Formation With Radiation-Bonded Cutting Edge
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Solution Overview
Problem
Existing methods for manufacturing tool blades lack precision and efficiency in forming sharp cutting edges, particularly in increasing the size and sharpening preformed teeth to desired dimensions and shapes, while maintaining mechanical integrity and cost-effectiveness.
Innovation Solution
A method involving a backing strip with preformed teeth, where abrasive particles and binding material are applied and bonded using radiation to form a binder layer, allowing for precise sizing and sharpening of teeth, potentially using tungsten carbide or super abrasive materials, and subsequent processing to achieve the desired cutting edge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional methods are used to form cutting edges on tool blades, then manufacturing simplicity is maintained, but manufacturing precision and sharpness of cutting edges deteriorate
Solution Approach 1:
The backing strip is preformed with teeth prior to introducing abrasive particles and binding material. This preliminary formation of tooth structure allows subsequent coating processes to precisely build up the cutting edge geometry, achieving high manufacturing precision while maintaining process efficiency
Solution Approach 2:
The manufacturing process is segmented into distinct stages: preforming teeth on backing strip, separately introducing abrasive particles, and separately introducing binding material. This segmentation allows each component to be optimized independently and combined with precise control over the final cutting edge geometry
2Measurement precision
If abrasive particles and binding material are applied in separate streams, then positioning precision of particles is improved, but process complexity increases
Solution Approach 1:
The particle application system is divided into separate streams: one for abrasive particles and one for binding material. This segmentation enables independent control of each material's flow, composition, and deposition characteristics, achieving precise positioning of abrasive particles on the tooth surfaces
Solution Approach 2:
The binding material acts as an intermediary that mediates the attachment of abrasive particles to the backing strip teeth. By controlling the binding material stream separately, the process achieves precise positioning of abrasive particles through the intermediary binding layer, which bonds the particles to the preformed teeth
3Adaptability or versatility
If teeth are preformed to undersize, then flexibility in final sizing is improved, but additional processing steps are required
Solution Approach 1:
Teeth are preformed to undersize on the backing strip before the coating process. This preliminary action establishes the basic tooth geometry and positioning, allowing flexible adjustment of final tooth size through controlled application of abrasive particles and binding material in subsequent steps
Solution Approach 2:
The final tooth size is achieved by changing parameters during the coating process: controlling the amount, size distribution, and packing density of abrasive particles, as well as the properties and thickness of the binding material layer. This allows flexible sizing adjustment without requiring precise preforming
4Productivity
If binding material is heated by radiation, then bonding efficiency is improved, but heat-affected zone is reduced
Solution Approach 1:
Radiation heating is applied locally to the binding material and abrasive particle coating on the tooth surfaces, rather than heating the entire backing strip uniformly. This localized heating achieves efficient bonding of the cutting edge materials while minimizing the heat-affected zone in the backing material, preserving its mechanical properties
Solution Approach 2:
The binding material serves as an intermediary layer that absorbs and concentrates radiation energy for localized heating. The radiation heats the binding material and abrasive particles to bonding temperatures while the thin nature of this intermediary layer limits heat conduction into the backing material, reducing the heat-affected zone
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
This method enables the creation of tool blades with enhanced cutting performance, improved mechanical integrity, and reduced production costs by allowing precise control over tooth size and shape, while minimizing heat-affected zones and retaining flexibility in the backing material.
Implementation Method 1
The binding material may be heated by laser radiation
Implementation Method 2
the binding material is heated by a beam of radiation to form the binder layer
Data Source
AI summary
There is provided a tool blade, comprising a backing strip particles of abrasive material and a binder layer of binding material which binds the abrasive particles along an edge of the backing strip, wherein the edge of the backing strip is pre-formed with teeth, on which the abrasive particles are bound by the binding material. A profiled cutting portion extends beyond the pre-formed teeth. The pre-formed teeth are shaped as generally triangular waves or are flattened at least partially along an upper edge on which the cutting portion is at least partially disposed. A method of making such a blade is also provided.