Abrasive Tool with Porous Support for Hard Material Removal
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Solution Overview
Problem
Classic machining processes for hard, brittle materials are time-consuming and costly, and existing grinding and polishing tools with metal or glass bonds are expensive and complex, with a short service life due to mechanical wear of the soft plastic matrix.
Innovation Solution
A tool with a geometrically indeterminate cutting edge featuring multiple abrasive layers on a substrate, where each layer has a distinct abrasive material, grain size, and support material concentration, allowing for adjustable friction and extended service life through a flexible plastic bond and additive manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional machining processes with bonded grains are used for hard, brittle materials, then material removal is achieved, but the process is time-consuming and costly
Solution Approach 1:
The patent changes the bonding mechanism from chemical bonds (traditional bonded grains) to mechanical interlocking through porous support structures. This parameter change in the bonding principle enables faster material removal while reducing processing time, as the abrasive particles can be more easily released and replaced during the machining process
2Strength
If metal or glass bonds are used in grinding and polishing tools, then tool strength is improved, but production costs increase and service life decreases due to mechanical wear
Solution Approach 1:
The patent creates a composite structure combining porous support material with abrasive particles, where the porous material provides mechanical strength and support while the abrasive particles perform the cutting function. This composite approach reduces production costs by using simpler, more readily available materials while extending service life through the ability to replace worn abrasives
Solution Approach 2:
The use of porous support material provides both structural integrity and facilitates the release and replacement of abrasive particles. The porous structure reduces material costs while maintaining tool strength, and enables easier maintenance and longer service life through particle replacement capability
3Adaptability or versatility
If the plastic matrix is soft to provide flexibility, then adaptability is improved, but the matrix wears down quickly reducing service life
Solution Approach 1:
The patent segments the tool structure into porous support material that provides mechanical strength and longevity, and replaceable abrasive particles that perform the cutting function. This segmentation allows the support structure to remain intact for extended periods while worn abrasives are simply replaced, thereby extending service life while maintaining flexibility
Solution Approach 2:
The patent enables discarding of worn abrasive particles and recovering/replacing them with fresh particles. This principle extends service life by allowing the durable porous support structure to be reused multiple times with different abrasive particles, maintaining flexibility while significantly extending the overall tool life
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 tool achieves longer service life and gentler material processing with improved surface quality, enabling flexible adaptation to various workpieces and reducing production costs by using additive manufacturing techniques.
Implementation Method 1
The plastic matrix is advantageously a conveyable material, for example a thermoplastic, so that it can be melted and flowed and conveyed for the additive manufacturing of the material processing tool
Implementation Method 2
conveyed for the additive manufacturing of the material processing tool
Implementation Method 3
Hard material grains which are used for material removal by machining with bonded grains are referred to as abrasive material
Data Source
Figure 1
Figure 2A~2C
Figure 3A~3B
AI summary
The invention relates to a tool (1) for material removal, comprising a first abrasive layer (3.1) applied to a substrate (2) with a first polymer bond (4.1), wherein the first polymer bond (4.1) comprises a first polymer matrix (5.1) serving as a bonding material in which all further components of the first polymer bond (4.1) are embedded, and a first abrasive material (6.1) having a first abrasive material hardness, a first grain size and a first concentration in the first polymer bond (4.1), thereby defining a first coefficient of friction of the first polymer bond (4.1), wherein the first polymer bond (4.1) comprises a first support material (7.1) having a first support material hardness that is less than the first abrasive material hardness and a first support material concentration in the first polymer bond (4.1), thereby defining a first hardness of the first polymer bond (4.1).The invention further relates to methods for the additive manufacturing of a tool (1) for material removal.