Abrasive Cutting-Off Wheel Metallic Insert Connection
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Solution Overview
Problem
Existing cut-off wheels with clamping disks connected directly to the abrasive cutting ring face challenges in achieving stable and efficient operation due to the need for precise indentations and limited continuous load capacity at high working speeds, leading to increased costs and material waste.
Innovation Solution
A metallic insert with projections and recesses is used to create a metal-metal connection between the clamping disks and the abrasive cutting ring, allowing for a form-fit and frictional connection that improves vibration behavior and reduces the thickness of the cutting wheel, enabling larger diameters with reduced material waste and energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If clamping disks are connected directly to the abrasive cutting ring, then the connection is simple, but the manufacturing precision requirements increase and continuous load capacity is limited
Solution Approach 1:
A metallic insert is introduced as an intermediary component between the clamping disks and the abrasive cutting ring. The insert contains projections that engage with recesses in the clamping disks, while its outer circumference interacts with the abrasive body through openings. This mediator transfers clamping forces without requiring precise indentations in the abrasive ring, resolving the contradiction between connection simplicity and manufacturing precision.
2Productivity
If larger cutting disc diameters are used, then cutting efficiency improves, but wheel thickness must increase to ensure stability and rigidity
Solution Approach 1:
The cutting wheel employs a composite structure combining a metallic insert with high mechanical strength and stiffness properties with the abrasive cutting ring. The metallic insert acts as a reinforcing skeleton that provides the necessary stability and rigidity for large diameter wheels, allowing the abrasive body to be thinner without compromising structural integrity. This enables larger diameters for higher productivity while reducing wheel thickness to minimize cutting gap and material waste.
3Stability of the object's composition
If thicker cutting discs are used, then stability and rigidity improve, but the cutting gap widens and material waste increases
Solution Approach 1:
The cutting wheel is segmented into functionally distinct components: a metallic insert dedicated to providing structural stability and rigidity, and a separate abrasive body dedicated to the cutting function. This segmentation allows each component to be optimized independently - the insert can be thick enough for stability while the abrasive body can be thin enough to minimize cutting gap width, thereby reducing material waste without compromising wheel stability.
4Reliability
If clamping disks are spaced from the insert, then vibration behavior improves, but the connection becomes less rigid
Solution Approach 1:
The connection between clamping disks and insert exhibits local quality variation: in the radial direction, projections and recesses provide form-fit connection for rigidity, while in the axial direction, spacing between clamping disks and insert allows vibration damping. This localized differentiation of connection characteristics enables simultaneous achievement of connection rigidity and improved vibration behavior.
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 solution enhances the vibration behavior and stability of the cut-off wheel, allowing for larger diameters with thinner wheels, minimizing material waste and energy consumption while maintaining operational efficiency.
Implementation Method 1
projections or recesses arranged on the side of the grinding wheel be provided on a metallic insert of the grinding wheel
Implementation Method 2
the frictional connection generated by the clamping disks
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
An abrasive cutting-off wheel having an abrasive cutting-off ring (1), the abrasive body (10) of which has bonded abrasive agents, wherein the abrasive cutting-off ring (1) is fixed, in the operational state, by two circular clamping discs (2, 3) which can be clamped together in the axial direction by means of central clamping flanges (4a, 4b) on a machine, and at least one clamping disc (2) is connected in a rotationally conjoint manner to the abrasive cutting-off ring (1) by means of interacting projections (5, 6) and recesses (7, 8), wherein the projections (5) or recesses (7) arranged on the abrasive cutting-off ring (1) are provided on a metallic insert (9) of the abrasive cutting-off ring (1), which metallic insert projects beyond the abrasive body (10) in the radial direction.