Cup Grinding Stone Axial Offset for Side Surface Machining
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Solution Overview
Problem
The existing method for manufacturing a cylindrical body by grinding the side surface of a polygonal-pillar or cylindrical grinding object is limited by the narrow width of the grinding stone, restricting the axial movement speed and resulting in prolonged working times even at high rotational speeds.
Innovation Solution
The method involves using a cup-type grinding stone with a side grinding stone portion and a bottom grinding stone portion, where the bottom grinding stone portion has finer abrasive grains than the side grinding stone portion. This setup allows for both rough-grinding and finish-grinding, with the cup-type grinding stone being axially rotated and offset to optimize grinding efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a wheel-shaped grinding stone with narrow width is used, then the device complexity is low, but the productivity is low due to restricted axial movement speed
Solution Approach 1:
The grinding stone is divided into multiple functional portions: a side grinding stone portion for rough-grinding and a bottom grinding stone portion for finish-grinding. This segmentation allows each portion to perform its specific function optimally, enabling higher axial movement speeds while maintaining low device complexity through a unified cup-type structure.
Solution Approach 2:
The cup-type grinding stone performs multiple functions simultaneously: rough-grinding via the side portion and finish-grinding via the bottom portion. This multi-functionality increases productivity by eliminating the need for separate grinding operations while keeping the device structure relatively simple.
2Productivity
If the rotational speed of grinding stone and grinding object is increased to compensate for narrow grinding stone width, then the productivity improves slightly, but the working time cannot be sufficiently shortened due to speed limits
Solution Approach 1:
The invention transitions from a two-dimensional side-grinding approach to a three-dimensional approach by adding bottom grinding capability. The cup-type grinding stone engages the grinding object from both the side and bottom surfaces simultaneously, effectively utilizing additional spatial dimensions to increase material removal rate and reduce working time without increasing rotational speed.
3Manufacturing precision
If a cup type grinding stone with different abrasive grain sizes is used, then the manufacturing precision is improved through separate rough and finish grinding, but the device complexity increases
Solution Approach 1:
Different regions of the grinding stone are assigned different abrasive grain characteristics: coarser grains on the side portion for rapid material removal and finer grains on the bottom portion for high-quality finish grinding. This local differentiation of quality achieves superior manufacturing precision while the integrated cup structure keeps overall device complexity manageable.
Solution Approach 2:
The rough-grinding function and finish-grinding function are merged into a single cup-type grinding stone device. By combining multiple grinding operations in one tool, the invention achieves high manufacturing precision without proportionally increasing device complexity, as the cup structure naturally accommodates both functional zones.
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 method significantly shortens the working time by allowing increased axial movement speed of the grinding object and reduces the likelihood of chipping in the ground product due to the curved boundary between the rough-ground and finished surfaces.
Implementation Method 1
grinding the side surface of the grinding object having a polygonal-pillar or cylindrical shape
Data Source
AI summary
Through the following steps (a) and (b), the side surface of a grinding object is ground to manufacture a ground product having a smaller diameter than that of the grinding object. In the step (a), a cup type grinding stone is disposed such that the central axis is parallel offset from a state where the central axis is orthogonal to the central axis of the grinding object. In the step (b), the cup type grinding stone is axially rotated so that the cup type grinding stone grinds the side surface of the grinding object while the grinding object is axially rotated and moved in the axial direction. Thereby, the outer peripheral surface of the grinding object is finish-ground by the bottom grinding stone portion of the cup type grinding stone while the grinding object is rough-ground by the side grinding stone portion to obtain a ground product.