Abrasive Mixture for Grinding Wheels with Low-Temperature Firing
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Solution Overview
Problem
Existing ceramic mixtures for grinding wheels, particularly for thin-film discs, face challenges in achieving regular grain distribution and require high production temperatures, which are not suitable for forming thin layers of other abrasive materials.
Innovation Solution
A ceramic-based mixture comprising 12-20 wt.% aluminum oxynitride abrasive grain, 62-72 wt.% ceramic binder, and 12-18 wt.% globular corundum with 5-100 µm marbles size, along with 2-5 wt.% potato starch, is mixed, compressed, dried, and fired at lower temperatures to create a bonded abrasive layer with improved grain distribution and reduced surface roughness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high production temperatures are used during binder firing to ensure grinding strength, then the binding strength is improved, but energy consumption increases and regular grain distribution is not achieved
Solution Approach 1:
The patent changes the firing temperature parameter from conventional high temperatures to a specific range of 700-790°C, which is sufficient to activate the ceramic binder and achieve adequate binding strength while significantly reducing energy consumption. This temperature optimization allows the binder to form strong bonds without requiring excessive thermal energy input.
Solution Approach 2:
The patent uses a composite binder system combining ceramic binder with organic additives (potato starch 2-5 wt% and PVA 1-3 wt%). The ceramic binder provides high-temperature stability and strength, while the organic additives enhance green strength and control firing behavior, allowing effective bonding at lower firing temperatures with reduced energy consumption.
2Strength
If conventional ceramic mixtures are used for thin-film discs, then grinding strength is maintained, but regular grain distribution is not achieved and surface quality deteriorates
Solution Approach 1:
The patent introduces globular corundum with a specific marble size of 5-100 μm as a local structural element. These uniformly sized spherical particles act as spacers that enforce regular spacing between abrasive grains, creating a more uniform local distribution pattern throughout the abrasive layer, which directly improves surface finish quality while maintaining grinding effectiveness.
Solution Approach 2:
The patent incorporates porosity-generating additives (bentonite 1-3 wt% and/or colloidal silica 1-3 wt%) that create a controlled porous structure in the abrasive layer. This porous network provides channels for coolant flow and chip evacuation, prevents grain clumping, and maintains uniform grain spacing, thereby improving both grain distribution regularity and surface quality without compromising structural integrity.
3Loss of substance
If thin layers of abrasive material are formed to save material and energy, then material consumption is reduced, but grinding efficiency may be compromised
Solution Approach 1:
The patent creates a composite abrasive layer combining aluminum oxynitride abrasive grains (12-20 wt%), ceramic binder (62-72 wt%), globular corundum (12-18 wt%), and organic additives. This composite structure provides enhanced binding strength and grain retention at lower layer thicknesses, maintaining grinding efficiency while reducing material consumption compared to conventional single-material abrasive layers.
Solution Approach 2:
The patent optimizes the thickness parameter of the abrasive layer to 0.5-5 mm, which is significantly thinner than conventional abrasive wheels. The improved binder system and grain distribution methodology enable this reduced thickness to maintain sufficient structural integrity and grinding performance, achieving material savings without sacrificing productivity.
4Strength
If high compression pressures are used to increase abrasive layer density, then layer strength is improved, but manufacturing complexity increases
Solution Approach 1:
The patent optimizes the compression pressure parameter to a specific range of 4-10 kN, which provides sufficient green strength for handling and subsequent processing without requiring excessively high pressures. This optimized pressure range achieves adequate layer density and bond strength while keeping the pressing equipment simple and the manufacturing process manageable.
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 enhances surface quality, reduces surface roughness, and decreases energy consumption by forming a low-temperature bonded abrasive layer on metal discs, enabling material and energy savings while maintaining high grinding efficiency.
Implementation Method 1
followed by firing at 700 to 790 °C for 45 to 80 minutes
Implementation Method 2
subsequently compressed at a pressure of at least 4 kN
Implementation Method 3
dried at 300 to 360 °C for 60 to 90 minutes
Data Source
AI summary
The invention relates to a mixture for abrasive grinding wheels, which comprises 12 to 20 wt. % abrasive grain aluminum oxynitride, 62-72 wt. % ceramic binder, 12 to 18 wt. % of globular corundum with a marbles size of 5 to 100 µm and 2 to 5 wt. % potato starch. It further relates to a process for the production of this abrasive mixture, wherein the mixture is mixed and moistened and subsequently compressed at a pressure of at least 4 kN, then dried at 300-360 °C for 60-90 minutes and then fired at 700 °C. up to 790 °C for 45 to 80 minutes.