Annular Grindstone Array for Plate Workpiece Grinding
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Solution Overview
Problem
Existing methods for grinding plate-shaped workpieces require positioning a chuck table with respect to two different arrays of grindstones for in-feed and creep-feed grinding, leading to a lengthy and wasteful process.
Innovation Solution
A method utilizing an annular array of grindstones for both in-feed and creep-feed grinding, where the chuck table is rotated and the grindstones are positioned to grind the workpiece with their lower surfaces during in-feed grinding and side surfaces during creep-feed grinding, eliminating the need for multiple grindstone arrays.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If two different arrays of grindstones are used for in-feed grinding and creep-feed grinding, then the grinding process can be completed with dedicated grindstones for each step, but the time required to position the chuck table with respect to two different arrays of grindstones increases significantly
Solution Approach 1:
The patent combines the functions of two separate grindstone arrays into a single annular array of grindstones. The annular array can perform both in-feed grinding and creep-feed grinding operations, eliminating the need to reposition the chuck table between two different grindstone arrays. This merging of functions directly reduces the positioning time while maintaining the precision benefits of dedicated grindstones for each grinding step.
Solution Approach 2:
The annular array of grindstones is designed to serve multiple functions: it can perform both in-feed grinding and creep-feed grinding. By making the grindstone system universal, the patent eliminates the need for separate positioning operations between different grindstone arrays, thereby reducing the overall processing time while maintaining grinding precision through appropriate selection of grinding modes.
2Loss of time
If only one type of grindstone is used for both in-feed grinding and creep-feed grinding, then the positioning time is reduced, but the wear on the grindstones increases significantly
Solution Approach 1:
The annular array of grindstones is segmented into multiple individual grindstones arranged in a circular pattern. This segmentation allows different portions of the annular array to be used for different grinding operations. Specifically, some grindstones can be dedicated to in-feed grinding while others perform creep-feed grinding, or the array can be reconfigured between operations. This segmentation reduces wear on individual grindstones compared to using a single grindstone for both operations, while maintaining the time efficiency of a unified positioning system.
Solution Approach 2:
The patent enables selective replacement or recovery of grindstones within the annular array. When certain grindstones become worn, they can be replaced or repositioned without affecting the entire system. This approach allows the system to maintain optimal performance by using fresh or less worn grindstones for critical operations, thereby reducing overall wear impact while maintaining the efficiency benefits of a single-array configuration.
3Productivity
If in-feed grinding is performed to achieve predetermined thickness, then the grinding speed is fast, but the grindstones wear out quickly and may not achieve the desired surface finish
Solution Approach 1:
The patent employs periodic action by alternating between in-feed grinding and creep-feed grinding operations. The in-feed grinding step removes material quickly to approach the target thickness, followed by a creep-feed grinding step that provides precise surface finishing. This periodic alternation between two grinding modes allows the system to achieve both high productivity through rapid material removal and high manufacturing precision through subsequent fine finishing, while the annular array configuration maintains efficient positioning throughout the process.
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 significantly reduces the time required for grinding, as only one array of grindstones is used, and minimizes grindstone wear by alternating the grinding surfaces, thereby extending the service life of the grindstones.
Implementation Method 1
moving the grindstones and the chuck table relatively to each other in directions perpendicular to the holding surface to grind an upper surface of the plate-shaped workpiece with the lower surfaces of the grindstones
Data Source
AI summary
One array of grindstones is used for in-feed grinding and creep-feed grinding. Therefore, it is not necessary to position a chuck table that is holding a plate-shaped workpiece with respect to two different arrays of grindstones. As a result, a period of time required to grind the plate-shaped workpiece can be shortened. Furthermore, lower surfaces of the grindstones are used for the in-feed grinding, whereas side surfaces of the grindstones are used for the creep-feed grinding. Consequently, the amount by which the grindstones are worn can be smaller than that in a case where the plate-shaped workpiece is ground to a predetermined thickness in only the in-feed grinding or the creep-feed grinding.