Bonded Abrasive Articles for Uniform Large-Particle Distribution
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing bonded abrasive articles face challenges in achieving homogeneous distribution of large abrasive particles, leading to inhomogeneities and density variations, which affect their performance in applications like gear grinding.
Innovation Solution
A method for forming bonded abrasive articles involves a slurry mixture of abrasive particles, bond precursor material, gelling agent, and additives, followed by gelation and conversion to a bonded abrasive body, ensuring homogeneous distribution of large abrasive particles through controlled porosity and bond material composition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If large abrasive particles are used in bonded abrasive articles, then cutting and grinding performance is improved, but homogeneous distribution of particles becomes difficult to achieve
Solution Approach 1:
The patent changes the physical and chemical parameters of the bond material, specifically using a glass-based composition with controlled softening point, viscosity, and thermal expansion coefficients. These parameter changes enable the bond material to effectively hold large abrasive particles (20-200 microns) while maintaining homogeneous distribution throughout the abrasive body.
Solution Approach 2:
The patent creates a composite material system combining glass-based bond material with abrasive particles. The composite structure leverages the complementary properties of glass (binding, homogeneity) and abrasive particles (cutting performance), achieving both homogeneous distribution and high productivity in large-scale grinding applications.
2Manufacturing precision
If high porosity is achieved in the bond material, then abrasive particle distribution is improved, but structural strength may be compromised
Solution Approach 1:
The patent deliberately incorporates porosity (30-70 vol%) into the glass-based bond material structure. This porosity creates space for abrasive particles to distribute uniformly while the glass matrix maintains structural integrity through its controlled composition and sintering characteristics.
Solution Approach 2:
The patent applies local quality by creating regions of different porosity and bond density within the abrasive body. Areas with higher porosity accommodate abrasive particles more effectively, while regions with denser bond material provide structural support, optimizing both particle distribution and strength.
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 resulting abrasive articles exhibit improved performance in large-scale cutting and grinding operations by maintaining uniformity and stability, enhancing their effectiveness in applications such as foundry operations.
Implementation Method 1
A method for forming bonded abrasive articles is disclosed including providing a slurry mixture, gelation of the slurry mixture, and conversion of the gelated slurry mixture to a bonded abrasive body
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
An abrasive article including a bonded abrasive having a body of a diameter of at least 260 mm and a volume of at least 20 cubic centimeters, the body also having a bond material including an inorganic material, abrasive particles having an abrasive particle size of at least 40 microns contained in the bond material, and a certain Homogeneity Factor.