Fiber-Reinforced Composite Grinding Wheel Carrier Reduces Spindle Load
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Solution Overview
Problem
Conventional grinding wheels made of metal suffer from high weight, leading to increased spindle load, reduced service life, and maintenance costs, as well as dynamic behavior issues such as slow rotation reversal and imbalance, which limits grinding speed and accuracy.
Innovation Solution
A carrier body for rotating grinding tools made of fiber-reinforced composite materials, such as carbon or glass fibers in a synthetic resin matrix, which reduces weight by up to 1/10 while maintaining high strength and rigidity, allowing for improved vibration damping and adjustability of natural frequency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metal carrier body is used for grinding wheels, then strength and rigidity are sufficient, but weight increases significantly leading to higher spindle load and reduced service life
Solution Approach 1:
The patent applies composite materials by combining fiber reinforcement (carbon fibers, glass fibers, aramid fibers, basalt fibers, or synthetic fibers) with a synthetic resin matrix to create a carrier body that achieves high strength-to-weight ratio. This composite structure provides the necessary mechanical strength while reducing weight to approximately one-tenth of conventional metal carrier bodies, thereby resolving the contradiction between strength requirement and weight reduction.
2Stability of the object's composition
If a metal carrier body is used, then structural stability is maintained, but dynamic behavior deteriorates with slow rotation reversal and increased imbalance
Solution Approach 1:
The patent changes the material parameters by using fiber-reinforced composite materials instead of traditional metal, which fundamentally alters the dynamic characteristics. The composite material structure enables faster rotation reversal and reduced imbalance tendencies while maintaining structural stability, thus resolving the contradiction between stability and dynamic responsiveness.
3Force
If a metal carrier body is used, then load-bearing capacity is sufficient, but energy consumption increases due to high moving mass
Solution Approach 1:
The fiber-reinforced composite material structure provides high specific strength and rigidity, enabling the carrier body to bear necessary loads while minimizing mass. This reduction in moving mass directly decreases the energy consumption for driving the grinding wheel, resolving the contradiction between load-bearing capacity and energy efficiency.
4Ease of manufacture
If a metal carrier body is used, then manufacturing simplicity is maintained, but maintenance costs increase due to reduced spindle service life
Solution Approach 1:
By changing the material parameters from metal to fiber-reinforced composite, the patent reduces the weight and moving mass of the grinding wheel, which directly decreases the load on the spindle and its bearings. This parameter change extends spindle service life and reduces maintenance costs, resolving the contradiction between manufacturing simplicity and reliability.
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 lightweight, high-strength carrier body reduces spindle load, extends tool life, decreases energy consumption, and enables higher grinding speeds with improved dimensional accuracy and surface quality, enhancing productivity and reducing maintenance needs.
Implementation Method 1
improved vibration damping and adjustability of natural frequency
Implementation Method 2
synthetic resin matrix
Implementation Method 3
relatively high thermal expansion coefficient of steel and aluminum, which leads to greater dimensional inaccuracy when heated during grinding
Data Source
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AI summary
In a rotating grinding- or cutting tool, in particular a grinding wheel or grinding roller, on one body, a coating of abrasive material, e.g. cubic boron nitride (CBN) or diamond is applied. The body (2, 12, 22, 32, 42) has two side walls (2a, 12a, 22a, 32a, 42a; 2a, 12a, 22a, 32a, 42a) which are connected to each other on their peripheral region, with the side walls being constructed with fiber-reinforced composite, in particular carbon fiber-, glass fiber- or synthetic fiber-reinforced composite.