Abrasive Article Infiltrating Segment Bonding
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Solution Overview
Problem
Existing abrasive tools face issues with breakage of the bond between abrasive members and their bases, leading to downtime, lost productivity, and safety hazards due to the ejection of abrasive particles at high speeds, necessitating improved bonding techniques.
Innovation Solution
An abrasive article comprising a base and an abrasive member with a network of interconnected pores filled with a metal infiltrant material, along with a distinct backing region made of a bonding composition including metal elements, which is laser welded to the base, ensuring strong and consistent bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional bonding methods are used to attach abrasive members to bases, then the structure is simple and easy to manufacture, but the bond breaks easily leading to safety hazards and downtime
Solution Approach 1:
The invention uses a composite bonding composition comprising a metal matrix and an infiltrant material (such as bronze or brass) to create a multi-phase backing region. This composite structure combines the strength of the metal matrix with the beneficial properties of the infiltrant, achieving superior bond strength (average break strength of at least 600 N/mm²) while maintaining a manageable structural complexity through a systematic manufacturing process.
2Strength
If stronger bonding is achieved through complex processes, then bond strength improves, but manufacturing complexity and cost increase
Solution Approach 1:
The invention achieves high bond strength by controlling specific parameters of the bonding composition, including the metal matrix composition, infiltrant material selection, porosity levels, and particle size distribution. The manufacturing process involves forming a porous backing region, infiltrating it with molten metal or alloy, and optionally sintering or heat treating. These controlled parameter changes enable consistent achievement of average break strength of at least 600 N/mm² through a systematic but not overly complex manufacturing sequence.
3Reliability
If the abrasive member is firmly bonded to prevent breakage, then safety improves, but the ability to replace worn abrasive members becomes more difficult
Solution Approach 1:
The invention segments the bonding structure into distinct functional zones: a porous backing region providing bonding strength, an infiltrant-filled transition zone, and the abrasive member itself. This segmentation allows the abrasive member to be firmly bonded for safety during operation while enabling controlled separation for replacement. The modular design with defined interfaces facilitates maintenance without compromising the strong bonding achieved during normal use.
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 solution achieves an average break strength of at least 600 N/mm² with low break strength variation, enhancing the durability and performance of abrasive tools by preventing catastrophic failures and improving cut speed to at least 1000 cm²/min through concrete slabs.
Implementation Method 1
a network of interconnected pores substantially filled with an infiltrant comprising a metal infiltrant material
Implementation Method 2
a backing region made of a bonding composition including metal elements, which is laser welded to the base
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
An abrasive article includes a base, an abrasive member comprising three distinct phases bonded to each other including abrasive particles, a metal matrix, and an infiltrant. The abrasive article further includes a backing region between the abrasive member and the base, wherein the backing region comprises a first phase and a second phase.