Abrasive Component Pressing and Infiltration for Strong Core Bonds
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Solution Overview
Problem
Existing abrasive tools face issues with bond breakage between the abrasive segment and the core, leading to safety hazards and downtime due to ejection of segments at high speed, and require separate processes like sintering or brazing for attachment, which are inefficient and costly.
Innovation Solution
A process involving a single pressing step to form precursor abrasive components on a core, followed by infiltration with a bond material to create a bonded abrasive tool, eliminating the need for separate attachment processes like sintering or brazing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If separate processes like sintering or brazing are used to attach abrasive segments to the core, then the bond strength can be improved, but the manufacturing complexity and production time increase
Solution Approach 1:
The patent combines the abrasive segment formation and attachment processes into a single integrated step. The abrasive mixture is pressed directly onto the core in a single operation, simultaneously forming the abrasive segment and creating the bond, thereby eliminating the need for separate sintering or brazing processes while maintaining bond strength
Solution Approach 2:
The bond material is prepared and positioned in advance within the pressing apparatus before the abrasive mixture is applied. This preliminary preparation of the bonding interface allows the attachment process to occur simultaneously with segment formation without requiring subsequent separate bonding operations
2Reliability
If separate attachment processes like sintering or brazing are used, then bond reliability can be improved, but production time and productivity are reduced
Solution Approach 1:
The patent merges the segment formation and attachment operations into one simultaneous pressing action, eliminating the sequential steps of separate sintering or brazing processes. This integration maintains bond reliability while significantly reducing production time and increasing productivity
Solution Approach 2:
The pressing operation continuously performs multiple functions simultaneously: forming the abrasive segment shape, compacting the abrasive particles, and creating the bond to the core. This continuous multi-functional action eliminates idle time between operations and maintains productive work flow throughout the process
3Strength
If traditional bonding methods are used, then bond strength can be achieved, but safety hazards increase due to high-speed ejection of segments
Solution Approach 1:
The integrated pressing process creates a more uniform and reliable bond between the abrasive segment and core by simultaneously compacting the abrasive particles and bonding them to the core in one operation. This enhanced bond reliability prevents segment breakage and high-speed ejection during operation, thereby reducing safety hazards
4Ease of manufacture
If abrasive segments are formed individually and then bonded to the core, then manufacturing flexibility is maintained, but production efficiency is reduced
Solution Approach 1:
The patent combines multiple abrasive segments and their attachment to the core into a single pressing operation. Multiple segments can be formed and bonded simultaneously in one process step, dramatically increasing production efficiency while maintaining the flexibility to accommodate different segment configurations and core designs
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
The process results in abrasive tools with improved mechanical strength and reduced breakage, meeting safety standards and enhancing productivity by integrating abrasive components directly to the core without additional steps.
Implementation Method 1
infiltrating at least one precursor abrasive component on the core to form an abrasive tool
Data Source
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AI summary
A process can include forming at least one precursor abrasive component on a core and infiltrating at least a portion of the precursor abrasive component. The precursor abrasive component can include a body including a metal bond matrix and abrasive particles. Infiltrating can be performed after forming the precursor abrasive component with an infiltrant material. The infiltrant material can include a metal element, an alloy or a combination thereof. In an embodiment, forming at least one precursor abrasive component can include simultaneously joining the precursor abrasive component to the core.