Angled Grinder Motion for Uniform Surface Roughness on Large Disks
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Solution Overview
Problem
Existing automatic grinding processing apparatuses struggle to achieve uniform surface roughness on large disk-shaped workpieces, leading to variations that can result in defective products.
Innovation Solution
A grinding processing apparatus with a rotary table, grinder, holding unit, and controller that controls the rotation and horizontal movement of the grinder to ensure consistent contact and pressure, using a combination of rotational speed, elevation, and horizontal movement to minimize surface roughness variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If automatic grinding processing apparatus is used to perform grinding processing, then variation in surface roughness is suppressed, but it is difficult to reduce variation in surface roughness over an entire surface of large workpiece
Solution Approach 1:
The grinder is configured to perform both radial movement (moving from center to outer peripheral side) and axial movement (repeated contact and separation from the workpiece surface). This dynamic motion pattern ensures that the entire surface of large disk-shaped workpieces is uniformly ground, reducing variation in surface roughness across the entire workpiece surface while maintaining manufacturing precision.
2Manufacturing precision
If grinder rotation axis is vertical to workpiece surface, then grinding is performed at single location, but surface roughness variation across entire surface cannot be reduced
Solution Approach 1:
The grinder's rotation axis is set at an angle of 0 degrees or more and less than 90 degrees relative to the vertical axis, enabling the grinder to dynamically move radially from the center to the outer peripheral side of the workpiece. This angular configuration provides the necessary flexibility to adapt to different grinding locations while maintaining manufacturing precision across the entire surface.
Solution Approach 2:
The grinder performs movement in multiple dimensions: radial movement along the workpiece surface from center to periphery, and axial movement for repeated contact and separation. This multi-dimensional motion capability allows the grinder to cover the entire workpiece surface effectively, achieving uniform surface roughness across large areas.
3Productivity
If grinder continuously contacts workpiece surface, then grinding efficiency is high, but surface roughness variation increases
Solution Approach 1:
The grinder performs periodic axial movement, repeatedly contacting and separating from the workpiece surface during radial movement. This periodic contact pattern prevents continuous grinding at single locations, reducing surface roughness variation while maintaining overall grinding efficiency through systematic coverage of the entire workpiece surface.
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 apparatus effectively reduces surface roughness variations by controlling the interaction between the grinder and workpiece, ensuring uniform processing across the entire surface of large disk-shaped workpieces.
Implementation Method 1
a rotary table configured to be rotatable and to hold a workpiece
Implementation Method 2
a grinder including a rotation unit and configured to grind a surface of the workpiece held by the rotary table by rotation of the rotation unit
Implementation Method 3
a horizontal movement slider configured to slide the holding unit in a horizontal direction
Data Source
Figure 1(A)~1(B)
Figure 2
Figure 3(A)~3(B)
AI summary
A grinding processing apparatus according to an embodiment includes: a rotary table configured to be rotatable and to hold a workpiece; a grinder including a rotation unit and configured to grind a surface of the workpiece held by the rotary table by rotation of the rotation unit; a holding unit configured to hold the grinder such that a rotation axis of the rotation unit forms an angle exceeding 0 degrees and being 60 degrees or less to a vertical axis; a horizontal movement slider configured to slide the holding unit in a horizontal direction in a state where a tip tool of the rotation unit is in contact with the workpiece; and a controller configured to control rotation of the rotary table and the rotation unit, and to control the grinder to linearly slide between a center side and an outer peripheral side of the workpiece.