Abrasive Article with Segmented Wear Life for AlTiC Grinding
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Solution Overview
Problem
Abrasive cup wheels used for edge grinding AlTiC materials face issues of reduced precision and inadequate finish due to wear, and existing longer-lasting materials do not meet performance requirements for certain applications.
Innovation Solution
An abrasive article comprising bonded abrasive segments with different bond compositions and wear life indices, arranged in a specific pattern on a substrate, which provides improved grinding performance by alternating abrasive segments with varying wear life and surface areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If cup wheels are made of longer lasting materials, then wear life is extended, but grinding precision and finish quality deteriorate
Solution Approach 1:
The cup wheel is divided into multiple abrasive segments with different bond compositions and wear life indices. Segments with higher wear life indices (more durable material) are positioned in regions where longevity is critical, while segments with lower wear life indices (softer material providing better finish) are positioned in regions where precision is paramount. This segmentation allows each zone to contribute its optimal characteristics to the overall grinding process.
Solution Approach 2:
Different regions of the cup wheel are assigned different local qualities through the use of abrasive segments with varying bond compositions. The wear life index varies by segment location, creating local optimization where each area of the wheel has properties tailored to its specific functional requirements. This local quality approach resolves the contradiction by allowing hard, durable material where needed while maintaining soft, precision-providing material in other areas.
2Strength
If cup wheels are made of harder materials, then wear resistance improves, but surface finish quality deteriorates
Solution Approach 1:
The invention applies local quality by varying the bond composition and wear life index across different segments of the cup wheel. Harder materials with higher wear resistance are applied locally in segments where durability is the priority, while softer materials that produce better surface finishes are applied in segments where finish quality is the priority. This localized material property variation allows simultaneous optimization of both wear resistance and surface finish in different wheel regions.
Solution Approach 2:
The cup wheel employs composite construction by combining multiple abrasive segments with different bond compositions into a single wheel structure. Each segment acts as a material composite with tailored properties, and the combination of these composites creates an overall wheel that exhibits both high wear resistance (from hard segments) and good surface finish capability (from softer segments), resolving the contradiction between these two opposing requirements.
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 abrasive article achieves enhanced grinding performance and extended wear life, maintaining precision and finish quality during the grinding of hard materials like AlTiC.
Implementation Method 1
Abrasive cup wheels are typically used for edge grinding AlTiC for HDDs
Data Source
AI summary
An abrasive article including a body comprising abrasive segments coupled to a major planar surface of a substrate, where a first abrasive segment comprises a first wear life index (w1) that is different than a second wear life index (w2) of the second abrasive segment by at least 5%.