Abrasive Articles via Layered Powder Deposition and Selective Heat Treatment
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Solution Overview
Problem
Traditional methods for manufacturing abrasive articles, such as vitrified bond and metal bond abrasive articles, face challenges including the need for specialized molds, high labor intensity, limitations in shape complexity, inhomogeneous components, and inefficiencies in the manufacturing process, particularly due to the requirement for high-powered lasers and inert atmospheres in selective laser sintering.
Innovation Solution
A method involving the sequential deposition of loose powder layers comprising abrasive particles, vitreous bond precursor particles, and organic compound particles, followed by selective heat treatment via conduction or irradiation, allowing for the formation of vitreous or metal bond abrasive articles without the need for high-powered equipment or inert atmospheres, enabling the creation of complex shapes with integrated cooling channels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional selective laser sintering is used to manufacture abrasive articles, then metal bonds can be formed, but high-powered lasers (30-150 watts) and inert atmospheres are required, increasing equipment complexity and manufacturing cost
Solution Approach 1:
The patent changes the key parameter of laser power from high (30-150 watts) to low (less than 30 watts) by modifying the powder composition to include organic compounds with specific melting points (50-250°C). This parameter change allows the process to proceed at lower temperatures and powers, eliminating the need for complex high-powered laser equipment and inert atmosphere maintenance while still achieving strong metal bonds through the organic compound-mediated bonding mechanism
Solution Approach 2:
The patent introduces organic compounds as intermediary substances that facilitate metal bonding at low temperatures. These organic compounds act as mediators by melting and flowing to bond metal particles together, then burning away to leave clean metal bonds. This intermediary mechanism enables strong bonding without requiring high-powered lasers or inert atmospheres, significantly simplifying the equipment needed
2Adaptability or versatility
If traditional molding methods are used to manufacture abrasive articles, then simple shapes can be produced, but complex shapes with undercuts or internal structures cannot be manufactured
Solution Approach 1:
The patent segments the manufacturing process into layer-by-layer deposition and selective heating steps, allowing complex three-dimensional shapes to be built incrementally. Each layer can be independently formed and bonded, enabling undercuts, internal structures, and complex geometries that cannot be achieved with traditional single-step molding. The segmented approach maintains manufacturing simplicity by using basic equipment for each step
Solution Approach 2:
The patent transitions from traditional two-dimensional molding to three-dimensional additive manufacturing by depositing and bonding powder layers sequentially in the z-dimension. This dimensional approach allows complex internal structures, cooling channels, and varied surface geometries to be incorporated without requiring complex mold designs, maintaining ease of manufacture while dramatically increasing shape versatility
3Manufacturing precision
If traditional molding methods are used, then manufacturing can proceed with simple equipment, but separation of components occurs during filling, leading to inhomogeneous abrasive components and density variation
Solution Approach 1:
The patent applies preliminary action by thoroughly pre-mixing the abrasive particles, metal particles, and organic compounds before deposition. This pre-mixing ensures uniform distribution of all components in the powder blend, preventing separation during the layer-by-layer deposition process. The preliminary preparation maintains component homogeneity without requiring complex in-process control mechanisms
Solution Approach 2:
The patent maintains continuous useful action by keeping the powder components in a uniform mixed state throughout the entire deposition and heating process. The organic compounds continue to bind particles together continuously as layers are deposited and heated, preventing component separation and density variation. This continuous bonding action ensures homogeneous abrasive components throughout the article
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
This method enables the efficient production of vitreous and metal bond abrasive articles with improved shape complexity and homogeneity, reducing manufacturing costs and labor intensity while eliminating the need for specialized molds and high-powered equipment.
Implementation Method 1
heating the layer to a temperature sufficient to melt the organic compound particles and bond the particles together
Implementation Method 2
the organic compound particles and bonding the abrasive and metal particles together to form a green body
Implementation Method 3
The green body then is ejected from the mold, and subsequently heated until the temporary organic binder is burned out
Implementation Method 4
the vitreous bond precursor is converted into a vitreous bond matrix
Data Source
Figure 1A
Figure 1B~1D
Figure 2~3
AI summary
The present disclosure provides methods of making a vitreous bond abrasive article and a metal bond abrasive article. The methods include sequential steps. Step a) includes a subprocess including sequentially: i) depositing a layer of loose powder particles in a confined region; and ii) selectively applying heat via conduction or irradiation, to heat treat an area of the layer of loose powder particles. The loose powder particles include abrasive particles and organic compound particles, as well as vitreous bond precursor particles or metal particles. The layer of loose powder particles has substantially uniform thickness. Step b) includes independently carrying out step a) a number of times to generate an abrasive article preform comprising the bonded powder particles and remaining loose powder particles. Step c) includes separating remaining loose powder particles from the abrasive article preform. Step d) includes heating the abrasive article preform to provide the vitreous bond abrasive article comprising the abrasive particles retained in a vitreous bond material, or to provide the metal bond abrasive article. Step d) further comprises burning out the organic compound material. A method of making a metal bond abrasive optionally includes infusing an abrasive article preform with a molten lower melting metal and solidifying the molten lower melting metal to provide the metal bond abrasive article. The present disclosure further provides a vitreous bond abrasive article precursor.