Diamond Processing via Rolling Unbound Grains
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Solution Overview
Problem
Conventional mechanical processing of diamonds is orientation-dependent, restricting efficiency and complicating the processing of diamonds with different crystalline structures, and is inefficient for various types of diamonds, including polycrystalline and gem diamonds.
Innovation Solution
A method using unbound diamond grains in a fluid between a mechanical part and the diamond surface, where the grains are subjected to a rolling motion to create microscopic fissures, allowing processing independent of the diamond's orientation, with the mechanical part making contact via the grains, which press into the surface and remove material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional mechanical processing methods (sawing, cutting, polishing) are used with tools having fixed diamond grains, then processing can be performed on diamond surfaces, but the processing efficiency strongly depends on the orientation of the diamond's crystalline structure in relation to the processing direction
Solution Approach 1:
The patent applies the dynamics principle by transitioning from static, fixed diamond grains on tool surfaces to dynamic, freely moving diamond grains suspended in a fluid medium. The grains are not rigidly fixed but move freely under fluid flow and acoustic field influence, allowing them to adapt their orientation and attack angle to the crystal structure being processed. This dynamic behavior enables effective material removal regardless of the diamond's crystalline orientation, resolving the contradiction between processing efficiency and adaptability to different crystal structures.
Solution Approach 2:
The patent introduces an intermediary fluid medium (such as water or oil) that carries the diamond grains to the workpiece surface. This fluid acts as a mediator between the diamond grains and the diamond surface being processed, allowing the grains to be delivered in a controlled manner and maintain freedom of movement. The fluid intermediary enables the grains to reach the surface from various angles and orientations, making the processing independent of the underlying crystal structure orientation.
2Manufacturing precision
If bound diamond grains are used on rotating cast iron disks for polishing, then material removal can be achieved, but the method is very hard for polycrystalline diamond with different crystal orientations
Solution Approach 1:
The patent replaces the static, bound diamond grains on rotating disks with dynamic, free-moving grains suspended in a fluid. These free grains can randomly orient themselves and attack the polycrystalline diamond surface from multiple angles, making them effective against grains with different crystal orientations. The dynamic movement allows each grain to find an optimal attack angle regardless of the underlying crystal structure, significantly reducing processing difficulty for polycrystalline materials.
Solution Approach 2:
The patent changes the state parameter of the diamond grains from bound/fixed to free/unbound, and changes the delivery mechanism from direct contact on rotating disks to fluid suspension. This parameter change allows the grains to maintain freedom of movement and random orientation during processing, which is particularly effective for polycrystalline diamond where crystal orientations vary across the surface.
3Productivity
If conventional processing operations are performed, then diamond material can be removed, but the removal rate strongly depends on the orientation of the processing direction in relation to the crystal
Solution Approach 1:
The patent employs dynamic, free-moving diamond grains that can change their orientation and attack angle during processing. Unlike fixed grains that must be aligned with specific crystal directions for effective material removal, the free grains in fluid suspension can adapt to any crystal orientation. This dynamic adaptability ensures consistent material removal rates regardless of the relationship between processing direction and crystal orientation.
Solution Approach 2:
The patent creates a universal processing system that works effectively on all diamond crystal orientations through the use of free-moving grains in fluid medium. The system is not limited to specific crystal directions or types of diamond (monocrystalline, polycrystalline, synthetic, natural) but provides consistent material removal across all orientations, making the process universally applicable.
4Ease of manufacture
If fixed diamond grains are drawn or pushed over the diamond surface by tools, then mechanical processing can be performed, but the method requires suitable processing direction to be determined by experiment and restricts the operation
Solution Approach 1:
The patent introduces a fluid medium as an intermediary that delivers diamond grains to the workpiece surface. This fluid intermediary simplifies the processing system by eliminating the need for complex tooling with fixed grains and multiple degrees of freedom. The fluid carries the grains to the surface, where they perform the cutting action, reducing the mechanical complexity of the processing device while maintaining effective material removal capability.
Solution Approach 2:
The patent replaces complex mechanical systems with fixed grains requiring precise orientation control with a simpler system using dynamic, free-moving grains in fluid. The freedom of movement of the grains eliminates the need for experimentally determining processing directions and reduces the degrees of freedom required in the machine design, as the grains self-adjust to effective attack angles.
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 increases processing efficiency and flexibility, allowing for higher removal rates across all crystal directions, reduces the importance of crystal orientation, and simplifies machine design, while minimizing temperature increase and damage risk.
Implementation Method 1
the diamond grains are subjected to a rolling motion such that the diamond grains move in relation to the mechanical part and the surface of the diamond over said surface
Implementation Method 2
The diamond grains, with the support of the mechanical part, press into the surface of the diamond while rolling, thus creating microscopic fissures in the surface
Implementation Method 3
diamond is mechanically processed in different ways, such as for example cleaving, sawing, cutting and polishing
Data Source
AI summary
Method and device for processing a surface (5) of a diamond (1) with a mechanical part (3) which is moved in relation to the surface (5) of the diamond (1), whereby unbound diamond grains (2) are provided in between the mechanical part (3) and the surface (5) of the diamond (1), whereby the mechanical part (3) subjects the diamond grains (2) to a rolling motion over the surface (5) of the diamond (1), such that the diamond grains (2) move in relation to the mechanical part (3) and the surface (5) of the diamond (1), whereby the mechanical part (3) makes a mechanical contact with the surface (5) of the diamond (1) via the diamond grains (2), whereby this mechanical contact represents a contact length (8) over which the diamond grains (2) roll on the surface (5) of the diamond (1), mainly according to the direction of the relative motion of the mechanical part (3) in relation to the surface (5) of the diamond (1) and, whereby the diamond grains (2), with the support of the mechanical part (3), press themselves in the surface (5) of the diamond (1) while rolling, as a result of which microscopic fissures (6) are created in the latter surface (5) which then gradually crumbles off.