High-Porosity CBN Grinding Stone Homogeneous Structure
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Solution Overview
Problem
Conventional high-porosity CBN vitrified grinding stones face issues with abrasive grain agglomeration and insufficient bonding, leading to reduced grinding stone life and increased risk of work material burn due to low filling volume and inadequate bond strength around abrasive grains and hollow fillers.
Innovation Solution
A high-porosity CBN vitrified grinding stone with a homogeneous structure is achieved by bonding CBN abrasive grains with large-diameter and small-diameter inorganic hollow fillers, using an inorganic bonding agent, where the small-diameter filler is interposed between the abrasive grains and large-diameter filler to enhance dispersion and bonding, maintaining high porosity while preventing agglomeration and burn.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a hollow filler having a single particle size at a fixed filling volume is used to form pores, then high porosity is achieved and grinding heat is easily released, but agglomeration of the hollow filler causes abrasive grains to locally drop off and bond strength is insufficient
Solution Approach 1:
The patent applies local quality by using two different particle sizes of hollow fillers (first and second particle diameters) to create different local structures within the grinding stone. The smaller particle size hollow filler fills gaps between larger particles, creating a more uniform distribution that prevents agglomeration while maintaining high porosity. This local variation in filler size ensures both heat release capability and structural integrity throughout the grinding stone.
Solution Approach 2:
The patent employs composite materials by combining hollow fillers of two different particle sizes within the same grinding stone structure. This composite approach allows the smaller hollow filler particles to interlock with and support the larger particles, creating a synergistic effect that prevents agglomeration while maintaining high porosity. The combination of different sized hollow fillers with abrasive grains and bonding agent creates a multi-component composite structure that resolves the contradiction between porosity and reliability.
2Quantity of substance
If the filling volume of hollow filler is increased to maintain high porosity, then grinding heat release is improved, but the bond strength around abrasive grains and hollow filler becomes insufficient
Solution Approach 1:
The patent applies parameter changes by optimizing the ratio between the first and second particle diameters of hollow fillers, as well as their respective filling volumes. By carefully controlling these parameters, the patent achieves a balance where the smaller hollow filler particles (with diameter of 1/5 to 1/2 of abrasive grain diameter) fill the interstices between larger particles and abrasive grains, creating a densely packed yet porous structure that maintains both high heat dissipation capability and sufficient bond strength throughout the grinding stone matrix.
3Object-affected harmful factors
If hollow filler is used to create pores for heat release, then grinding burn is suppressed, but abrasive grains experience local drop off due to agglomeration
Solution Approach 1:
The patent applies the intermediary principle by using the smaller particle size hollow filler as a mediator between the larger hollow filler particles and the abrasive grains. The smaller hollow filler particles fill the gaps and act as spacers that prevent direct contact and agglomeration of larger hollow filler particles, thereby stabilizing the abrasive grain distribution. This intermediary structure ensures uniform abrasive grain spacing while maintaining the porosity needed for heat release and preventing grinding burn.
Data Source
AI summary
In a high-porosity CBN vitrified grinding stone having a homogeneous structure, a CBN abrasive grain, a large-diameter inorganic hollow filler having an average particle diameter in a range from a grain size one class coarser to a grain size one class finer with respect to a class indicating a grain size of the CBN abrasive grain, and a small-diameter inorganic hollow filler having an average particle diameter of ⅕ to ½ of that of the CBN abrasive grain are bonded by an inorganic bonding agent.