Additive Manufacturing of Shaped Abrasive Particles for Geometry Precision
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing abrasive particle manufacturing methods fail to produce shaped abrasive particles with precise geometries and consistent quality, limiting their effectiveness in material removal operations.
Innovation Solution
The use of an additive manufacturing process to form shaped abrasive particles, allowing for the creation of bodies with self-similar features, corner microprotrusions, and controlled deposition of print materials to achieve desired shapes and dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional fusion, sintering, or chemical ceramic processes are used to produce shaped abrasive particles, then the manufacturing process is established, but the manufacturing precision and geometry control are insufficient
Solution Approach 1:
The patent replaces traditional mechanical/thermal forming processes (fusion, sintering, chemical ceramic) with a digital printing process. The digital printing process uses a nozzle to deposit material layer by layer according to digital model data, enabling precise control of particle geometry without requiring complex thermal or chemical processing steps.
Solution Approach 2:
The patent changes the fundamental parameter of material state from solid/liquid mixtures requiring thermal processing to a printable paste or slurry formulation. This parameter change enables direct digital fabrication of the abrasive particles with precise geometric control, as the material can be deposited in the desired shape and then sintered to final density.
2Manufacturing precision
If existing molding processes are used to form shaped abrasive particles, then some shaping capability is achieved, but the quality consistency and precision are limited
Solution Approach 1:
The patent uses digital copying of the desired particle geometry into the manufacturing process. A digital model of the abrasive particle is created and stored as data, which is then directly printed layer by layer. This digital copying approach eliminates the need for physical molds and ensures perfect geometric consistency across all particles, as the same digital data can be reused indefinitely.
Solution Approach 2:
The patent segments the formation of a single abrasive particle into multiple thin layers deposited sequentially by the printing nozzle. Each layer is deposited with precise control over material placement, and the layers are bonded together through sintering. This segmentation into layers enables complex geometries to be built up systematically, achieving high shape consistency without requiring complex single-step molding processes.
3Productivity
If conventional methods are used to produce abrasive particles, then production is possible, but productivity and efficiency in material removal operations are limited
Solution Approach 1:
The patent performs preliminary action by forming the abrasive particles with their final operational geometry during the printing process itself, rather than requiring post-forming operations. The digital printing process creates particles with precise self-similar features, corner microprotrusions, and controlled dimensions directly, eliminating subsequent processing steps and ensuring high geometry quality that directly enhances material removal efficiency.
Data Source
Figure 1A~1B
Figure 1C~1E
Figure 2
AI summary
A method of forming a shaped abrasive particle includes having a body formed by an additive manufacturing process.