Composite Grinding Wheel for Spiral Profiles
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Solution Overview
Problem
Existing grinding processes for spiral-shaped profiles, such as those in recirculating ball screws, are inefficient due to the need for multiple passes with different grinding wheels, leading to lengthy execution times and potential deformation from excessive heating, which compromises precision and quality.
Innovation Solution
A grinding wheel comprising two abrasive discs with different properties, one for roughing and one for finishing, coupled in a rigid or reversible manner, allowing for simultaneous operation on a spiral-shaped track to achieve both steps in a single pass while maintaining geometrical stability and reducing heat-related issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple grinding wheels with different grain sizes are used for roughing and finishing, then manufacturing precision is improved, but productivity deteriorates due to lengthy execution times
Solution Approach 1:
The patent combines roughing and finishing grinding functions into a single composite grinding wheel by integrating two abrasive layers with different grain sizes. The first abrasive layer (coarser grain) performs roughing while the second abrasive layer (finer grain) performs finishing, allowing both operations to occur simultaneously in one pass rather than requiring sequential replacement of wheels.
Solution Approach 2:
The composite grinding wheel serves multiple functions simultaneously - it acts as both a roughing wheel and a finishing wheel in a single tool. This multi-functional design eliminates the need for tool changes and enables both roughing and finishing operations to be performed on the spiral groove in one continuous process.
2Manufacturing precision
If multiple grinding passes are performed, then manufacturing precision is improved, but loss of time increases due to wheel replacement and repeated operations
Solution Approach 1:
The patent merges the functionality of multiple grinding wheels into a single composite wheel structure, eliminating the time-consuming wheel replacement step. The first abrasive layer handles roughing and the second abrasive layer handles finishing, both simultaneously during one continuous operation without interruption.
3Manufacturing precision
If finishing grinding is performed with high pressure, then manufacturing precision is improved, but object-generated harmful factors increase due to wheel heating and profile deformation
Solution Approach 1:
The composite grinding wheel applies different local qualities through its layered structure - the first abrasive layer with coarser grain provides aggressive material removal with better heat dissipation, while the second abrasive layer with finer grain provides precise finishing. This distribution of grinding functions across different layers reduces concentrated heat generation that would otherwise deform the workpiece profile.
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
This approach significantly reduces processing time, enhances thermal management, and maintains precision by allowing a single-pass complete processing of spiral-shaped profiles, minimizing the risk of deformation and elongation.
Implementation Method 1
a grinding wheel (1) comprising two abrasive outer profiles (5, 6) having an arcuate shape, with an axisymmetric shape about an axis (X) of the grinding wheel (1) and axially positioned alongside each other
Data Source
Figure 1~3
Figure 2
Figure 4
AI summary
Described is a grinding wheel for grinding spiral-shaped profiles, comprising a first abrasive disc (1a) and a second abrasive disc (1b), arranged side by side and positioned coaxially, the two discs (1a, 1b) being rigidly coupled to each other and each having an abrasive peripheral profile (5a, 5b) in such a way that the two abrasive discs (1a, 1b) engage inside two respective grooves (4a, 4b) of at least one spiral-shaped profile (3) of a mechanical member (2), wherein the two discs (1a, 1b) have different abrasive properties to define different levels of surface roughness of the grooves (4a, 4b).