Abrasive Machining Segment Layering for Low-Porosity Sintering
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Solution Overview
Problem
Existing methods for producing machining segments for abrasive machining tools result in high porosity, leading to reduced tool lifetime due to insufficient holding forces for hard material particles, and are economically inefficient due to mold wear and lower average densities at reduced compression pressures.
Innovation Solution
A method involving layer-by-layer application of metallic powder material and hard material particles, allowing the particles to be exclusively within the green body, enabling high compression pressures and sintering without pressure, resulting in machining segments with porosity below 10% and average density above 90% of the theoretical density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If hard material particles are arranged in random distribution in metallic powder material and compacted under pressure, then machining segments can be produced, but the porosity is high (10-25% by volume) leading to reduced tool lifetime
Solution Approach 1:
The machining segment is divided into a green body (metallic powder material) and hard material particles that are embedded within it. This segmentation allows the metallic powder material to provide structural integrity and low porosity while the hard material particles provide cutting functionality, resolving the contradiction between ease of manufacture and tool lifetime.
Solution Approach 2:
The hard material particles are preliminarily arranged in a desired pattern before the compaction process. This preliminary arrangement ensures that particles are properly positioned within the green body before compaction, preventing them from protruding and causing mold wear, while also ensuring they are securely embedded to prevent premature loss during machining, thereby extending tool lifetime.
2Ease of manufacture
If compression pressure is reduced below 850 MPa to reduce mold wear, then mold costs decrease, but average density decreases and porosity increases
Solution Approach 1:
The hard material particles are preliminarily arranged within the green body before compaction. This preliminary positioning prevents particles from protruding during compaction, eliminating mold wear and allowing the use of lower compression pressures (below 850 MPa) without sacrificing density or porosity control, thus resolving the contradiction between mold cost and manufacturing precision.
Solution Approach 2:
The green body acts as an intermediary that holds the hard material particles in place during compaction. This intermediary structure prevents direct contact between protruding particles and the mold, eliminating wear while allowing lower compression pressures to be used, thereby resolving the contradiction between ease of manufacture and manufacturing precision.
3Measurement precision
If hard material particles protrude from the surface of the compacted green body, then they can be visible for inspection, but they damage the mold during compaction increasing wear and costs
Solution Approach 1:
The hard material particles are preliminarily arranged within the green body at positions that ensure they will be embedded after compaction. This preliminary positioning allows inspection of particle placement before compaction while ensuring that no particles protrude during compaction, eliminating mold wear while maintaining the ability to inspect particle positions.
Solution Approach 2:
The green body serves as an intermediary that contains the hard material particles during compaction. This intermediary prevents direct contact between particles and mold, eliminating wear while allowing particle positions to be inspected through the green body or by measuring before compaction.
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 approach extends tool lifetime by ensuring hard material particles are securely embedded, reducing mold wear, and enabling production at higher compression pressures, thus producing machining segments with enhanced strength and reduced porosity, improving both performance and economic viability.
Implementation Method 1
compacted under pressure to a compact body, with compaction of the compact body as far as the final geometry of the machining segment
Implementation Method 2
sintered in the subsequent sintering process by unpressurized sintering at temperatures between 900 and 1300° C.
Data Source
AI summary
A method of producing a machining segment, in which a green body (51) is constructed from a machining zone (54), wherein the machining zone (54) is produced from a first metallic powder material (56) and hard material particles (58), the green body (51) is compacted under pressure with a compression pressure to result in a compact body and the compact body is sintered thermally at a sintering temperature to result in the finished machining segment, wherein the machining zone (54) is produced by layer-by-layer application of material layers of the first metallic powder material (56) and particle layers of the hard material particles (58), wherein the hard material particles (58) in one particle layer are placed into the previously applied material layer of the first metallic powder material (56).