Abrasive Flap Reinforcement with Cured Resin
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Solution Overview
Problem
Abrasive tools experience premature wear and reduced material removal due to cyclical deflection of abrasive flaps during machining, leading to a shorter useful life and lower total material removal.
Innovation Solution
Reinforcing abrasive flaps with a cured filling resin, such as thermosets or phenolic resin, to reduce cyclical deflection and increase stiffness, thereby extending the tool's life and material removal capacity without increasing base wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If abrasive flaps are used without reinforcement, then the tool structure is simple and easy to manufacture, but the cyclical deflection is pronounced causing premature wear and reduced useful life
Solution Approach 1:
The patent applies composite materials by incorporating a filling resin (such as thermosetting resin) into the base material of the abrasive flaps. This creates a composite structure where the filling resin reinforces the base material, reducing cyclical deflection during operation while maintaining the overall simplicity of the flap design. The composite nature allows the flaps to withstand repeated bending without premature failure.
Solution Approach 2:
The patent changes the physical and mechanical parameters of the base material by adding filling resin. This modification alters the stiffness, strength, and deflection characteristics of the abrasive flaps. The filling resin content and distribution are controlled to achieve optimal reduction in cyclical deflection while preventing premature breakout of abrasive material.
2Duration of action of moving object
If abrasive flaps are reinforced with filling resin, then cyclical deflection is reduced and useful life is extended, but the manufacturing process becomes more complex
Solution Approach 1:
The filling resin is incorporated into the base material during the manufacturing process before the abrasive flaps are assembled onto the support. This preliminary incorporation ensures uniform distribution of the reinforcing material throughout the base structure, optimizing the reduction of cyclical deflection from the outset and eliminating the need for post-assembly reinforcement steps.
Solution Approach 2:
The manufacturing process parameters are adjusted to accommodate the filling resin incorporation. This may include modifications to the base material formulation, curing conditions, or processing temperatures. These parameter changes enable the production of reinforced flaps with controlled resin content and distribution, achieving the desired mechanical properties while maintaining manufacturing efficiency.
3Quantity of substance
If abrasive material is subjected to pronounced cyclical deflection, then the tool is simpler to produce, but the abrasive material is torn out before wearing out reducing total material removal
Solution Approach 1:
The composite structure with filling resin provides enhanced mechanical strength and fatigue resistance to the base material. This allows the abrasive material to remain securely anchored during repeated bending cycles, preventing premature breakout and ensuring that the full material removal potential of each abrasive particle is utilized before the flaps wear out.
Solution Approach 2:
The structural parameters of the base material are modified through filling resin incorporation to increase its resistance to cyclic loading. This changes the deflection characteristics and stress distribution within the flaps, reducing the magnitude of cyclical bending stresses that cause abrasive material detachment and extending the operational life of the abrasive tool.
4Quantity of substance
If the abrasive flaps are not reinforced, then the manufacturing cost is lower, but the ratio of base wear to total material removal is higher
Solution Approach 1:
The filling resin creates a composite base material with improved mechanical properties, including higher strength and reduced deflection. This prevents premature breakout of abrasive material, ensuring that the base wears down at a controlled rate through normal fluffing mechanisms rather than through premature failure, thereby optimizing the ratio of useful material removal to base consumption.
Solution Approach 2:
The mechanical parameters of the base material are altered through filling resin incorporation to achieve optimal wear characteristics. The reinforced structure reduces excessive deflection that would otherwise cause accelerated base wear and premature abrasive loss, maintaining a favorable balance between base durability and total material removal efficiency.
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 reinforcement of abrasive flaps with a cured filling resin significantly reduces cyclical deflection, resulting in a longer useful life and greater total material removal while minimizing base wear and respirable dust production.
Implementation Method 1
at least one of the abrasive flaps has a cured filling resin for reinforcement
Implementation Method 2
Reinforcing the abrasive flaps greatly reduces the cyclical deflection thereof
Data Source
AI summary
An abrasive tool includes a support, on which a plurality of abrasive flaps is arranged. The abrasive flaps each have a base and abrasive material, which is attached to the base by means of a binder. To increase the useful life and total material abrasion, the abrasive flaps are reinforced by a cured filling resin. The reinforcement of the abrasive flaps reduces the cyclical deflection thereof around a zero position due to workpiece machining, thereby avoiding increased wear on the abrasive flaps.