Composite Shaped Abrasive Particles for Stable Material Removal
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Solution Overview
Problem
Existing abrasive technologies fail to produce composite shaped abrasive particles with improved performance and efficiency for material removal operations.
Innovation Solution
A method involving the formation of a mixture with specific rheological characteristics, including a ceramic powder and liquid, which is extruded through a die and printed onto a production tool to create precursor shaped abrasive particles, followed by processes like drying and sintering, and attachment of additional abrasive particles to the surface, resulting in composite shaped abrasive particles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional abrasive particles are used, then material removal operations can be performed, but the performance and efficiency are insufficient
Solution Approach 1:
The patent applies composite materials by combining a shaped body (such as a sintered abrasive body or ceramic substrate) with additional abrasive particles attached to its surface. This composite structure integrates the mechanical strength and shape stability of the body with the high abrasive capability of the attached particles, thereby simultaneously improving both the reliability and productivity of the abrasive article.
Solution Approach 2:
The abrasive particle is segmented into two functional components: a shaped body that provides structural support and shape stability, and separate abrasive particles that are attached to the surface to provide cutting action. This segmentation allows each component to be optimized independently for its specific function, leading to improved overall performance.
2Productivity
If abrasive particles are attached to the surface of the mixture, then material removal capability is improved, but the complexity of the forming process increases
Solution Approach 1:
The shaped body is formed first with the desired geometry and shape stability before the abrasive particles are attached to its surface. This preliminary formation of the body structure simplifies the overall process by establishing the structural foundation beforehand, making the subsequent attachment of abrasive particles a simpler finishing step rather than a complex integrated process.
Solution Approach 2:
A bonding agent or adhesive layer acts as an intermediary between the shaped body and the abrasive particles, facilitating their attachment. This intermediary substance simplifies the forming process by providing a straightforward bonding mechanism, avoiding the need for complex mechanical interlocking or multi-step assembly procedures.
3Stability of the object's composition
If composite shaped abrasive particles are formed, then shape stability is maintained, but the manufacturing process becomes more complex
Solution Approach 1:
The composite structure of a shaped body with attached abrasive particles provides inherent shape stability through the rigid body, while the manufacturing complexity is managed by using standardized forming techniques for the body and simple attachment processes for the particles, thereby achieving stability without excessive complexity.
Solution Approach 2:
The manufacturing process utilizes parameter changes such as temperature and pressure during the formation of the shaped body (e.g., sintering or curing processes) to achieve shape stability. These controlled parameter changes allow the body to be formed with precise dimensional stability while keeping the overall manufacturing process manageable through standard industrial techniques.
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 method enhances the performance and efficiency of abrasive particles by maintaining shape stability and improving material removal capabilities, such as in grinding and polishing operations.
Implementation Method 1
which is extruded through a die and printed onto a production tool to create precursor shaped abrasive particles
Implementation Method 2
followed by processes like drying and sintering
Data Source
AI summary
An abrasive particle including a shaped abrasive particle including a body having a plurality of abrasive particles bonded to at least one surface of the body of the shaped abrasive particle.