Diamond Tool Multi-Layer Abrasive Brazing
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Solution Overview
Problem
Diamond tools with single abrasive layers have limited service life and performance due to non-uniform abrasive distribution and mechanical properties, leading to stratification and reduced cutting/grinding ability.
Innovation Solution
A method of forming multiple abrasive layers on a shank using concave portions and a combination of brazing and electroplating methods, where abrasives are bonded inside the concave portions with a bonding material, allowing for uniform distribution and fusion bonding to enhance retention and performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If a single abrasive layer is formed using conventional methods, then the manufacturing process is simple, but the service life is limited due to non-uniform abrasive distribution and mechanical properties
Solution Approach 1:
The abrasive layer is segmented into multiple layers with different depths and orientations. The patent forms a first abrasive layer at a first depth and a second abrasive layer at a second depth, creating a multi-layered structure that extends tool life by providing sequential abrasive exposure as the tool wears.
Solution Approach 2:
The patent transitions from a single-plane abrasive distribution to a multi-dimensional layered structure. By distributing abrasives at different depths and orientations within the bonding material, the invention creates a three-dimensional abrasive architecture that maintains cutting performance throughout the tool's service life.
2Manufacturing precision
If abrasives are non-uniformly dispersed in a single layer, then the manufacturing process is simple, but stratification occurs reducing cutting and grinding ability
Solution Approach 1:
The patent applies local quality by creating regions with different abrasive concentrations and orientations. The first and second abrasive layers are formed with specific local distributions tailored to different functional requirements, ensuring uniform overall performance while allowing localized optimization.
Solution Approach 2:
The invention changes the distribution parameters of abrasives by controlling their depth, orientation, and concentration in different layers. By adjusting these parameters during the brazing process, the patent achieves uniform abrasive distribution that prevents stratification while maintaining manufacturing feasibility.
3Strength
If mechanical bonding is used between abrasives and bonding material, then the manufacturing process is simple, but the retention force is relatively weak
Solution Approach 1:
The patent employs composite materials by combining different bonding mechanisms within the bonding material. The bonding material contains both mechanically bonded abrasives and chemically bonded abrasives, creating a composite bonding system that leverages the strengths of both bonding types to enhance overall abrasive retention.
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 method extends the service life of diamond tools by ensuring uniform abrasive distribution and retention, maintaining consistent cutting/grinding performance and reducing manufacturing costs through optimized concave portion design and fusion bonding.
Implementation Method 1
a fusion-bonded lower abrasive layer, and a fusion-bonded upper abrasive layer
Implementation Method 2
a combination of brazing and electroplating methods
Data Source
AI summary
The present invention relates to a diamond tool and a method of manufacturing the same, wherein multiple abrasive layers are formed through a brazing or electroplating method, thereby improving the performance and service life of the tool. According to the method of the present invention, a plurality of concave portions are formed in a surface of the shank. A bonding paste is coated into the concave portions and abrasives are dispersed in the bonding paste to thereby form a lower abrasive layer. Again, a bonding material is coated on the lower abrasive layer and abrasives are dispersed in the bonding material to thereby form an upper abrasive layer. Then, a heat treatment is executed to fusion-bond the bonding material and abrasives onto the surface of the shank. Therefore, the diamond tools manufactured through a multiple brazing or electroplating method according to the invention can significantly extend the service life thereof, which has been a detrimental weakness of the conventional diamond tools having a single abrasive layer, in spite of various advantages of the brazing and electroplating methods. Furthermore, multiple abrasive layers can be formed inside the concave portions having a desired spacing, width and depth, thereby significantly improving the service life and the cutting performance of diamond tools.