Bonded Abrasive Articles with Erectly-Oriented Grinding Layers

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Solution Overview

Problem

Conventional bonded abrasive articles lack the necessary performance to efficiently abrade materials quickly while maintaining tight tolerances without damaging workpieces, particularly in applications requiring high-speed grinding operations.

Innovation Solution

A bonded abrasive article comprising a matrix and a grinding layer with erectly-oriented abrasive particles, where the grinding layer is disposed on the surface or within the article, enhancing cutting and grinding performance by increasing the total cut capacity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional bonded abrasive articles are used, then the structure is simple and easy to manufacture, but the cutting and grinding performance is insufficient with low total cut capacity

Engineering Contradiction:

Improvetotal cut capacityVSAvoidarticle structure

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The abrasive article is segmented into distinct functional layers: a matrix layer containing matrix abrasive particles and binder, and a surface grinding layer containing grinding abrasive particles and binder. This segmentation allows each layer to be optimized for its specific function, with the matrix providing structural support and the surface layer providing enhanced cutting performance, thereby increasing total cut capacity while maintaining manufacturing feasibility through layered construction

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the abrasive article are given different properties: the matrix layer has a composition and structure optimized for structural integrity and material removal, while the surface grinding layer has a composition and structure optimized for cutting edge sharpness and grinding performance. This local differentiation of properties enables the surface layer to deliver superior cutting and grinding performance without compromising the overall article structure

Inventive Principle:

Principle #3Local quality

2Speed

If high-speed grinding operations are performed, then material removal speed increases, but workpiece damage occurs due to excessive heat and pressure

Engineering Contradiction:

Improvegrinding speedVSAvoidworkpiece damage

Core Design Contradiction:

SpeedVSObject-affected harmful factors

Solution Approach 1:

The invention changes the physical and chemical parameters of the abrasive particles and binder materials to enable high-speed operation. Specifically, the abrasive particles are selected and sized to maintain sharp edges at high speeds, and the binder materials are formulated to withstand high-speed generated heat and pressure without degrading, thereby allowing increased grinding speed without workpiece damage

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentEP3052271B1Bonded abrasive articles and methods

Publication Date: 2021.04.21 3M INNOVATIVE PROPERTIES CO

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AI summary

A bonded abrasive article having a matrix formed from matrix abrasive particles and a matrix binder; and a grinding layer having erectly-oriented abrasive particles and a grinding layer binder. The grinding layer is disposed on an exterior surface of the bonded abrasive article or is disposed at least partly within the interior of the bonded abrasive article.