Bonded Abrasive Article with Bulk Molding Compound Reinforcement
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Solution Overview
Problem
Existing bonded abrasive articles face challenges with wear, edge stability, and extended lifetime, particularly in material removal operations such as cutting and grinding, where they often experience spalling and reduced burst speed.
Innovation Solution
The development of abrasive articles comprising a body with abrasive particles embedded in a bond material that includes a bulk molding compound, reinforced with a woven reinforcing member, which enhances bonding and structural integrity, thereby improving wear resistance and burst speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional bond materials are used in abrasive articles, then manufacturing is simpler, but wear resistance and burst speed are insufficient
Solution Approach 1:
The patent applies composite materials by combining organic bond materials with inorganic fillers (such as alumina, silica, or magnesia) to create a hybrid bond material system. This composite approach provides both the flexibility and adhesion of organic materials and the hardness and wear resistance of inorganic materials, thereby improving wear resistance and burst speed while maintaining manageable manufacturing complexity.
Solution Approach 2:
The patent employs parameter changes by systematically varying the composition ratios, particle size distributions, and chemical formulations of the bond material to optimize performance. By adjusting these parameters, the patent achieves improved wear resistance and burst speed tailored to specific application requirements without overly complicating the manufacturing process.
2Strength
If reinforcing members are added to improve structural integrity, then burst speed increases, but manufacturing complexity increases
Solution Approach 1:
The patent uses composite materials by integrating reinforcing members (such as fibrous materials or mesh structures) into the abrasive article body. These reinforcing elements are combined with the bond material and abrasive particles to create a multi-phase composite structure that enhances structural integrity and burst speed while maintaining a manageable manufacturing process through established lamination and molding techniques.
Solution Approach 2:
The patent applies local quality by strategically placing reinforcing members in specific regions of the abrasive article where stress concentrations occur during operation. This targeted reinforcement approach optimizes structural integrity and burst speed in critical areas without unnecessarily complicating the overall article structure or manufacturing process.
3Productivity
If abrasive particles are densely packed to improve material removal efficiency, then productivity increases, but edge stability decreases
Solution Approach 1:
The patent applies local quality by creating regions with different abrasive particle concentrations and sizes within the bond material. Areas requiring high material removal efficiency have denser abrasive packing, while edge regions have optimized particle distributions that maintain structural stability and prevent edge breakdown, thereby balancing productivity and edge stability.
Solution Approach 2:
The patent employs parameter changes by systematically varying abrasive particle size distributions, shape characteristics, and packing densities to optimize both material removal efficiency and edge stability. By controlling these parameters, the patent achieves high productivity in cutting and grinding operations while maintaining edge integrity and reducing premature wheel failure.
Data Source
AI summary
An abrasive article with an abrasive body a reinforcing member disposed within the body and a bond material that includes a bulk molding compound material. The abrasive article can have an average burst speed of at least (Formula (I)) wherein c is the circumferences of the wheel in mm.26800 RPM-27 RPMmm*C(I)