Electrodeposited Wire Tool With Thin Coating Abrasive Grains
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Solution Overview
Problem
Electrodeposited wire tools with super abrasive grains face issues of excessive abrasive grain deposition, leading to waste and reduced tool life due to the high conductivity of thick coating layers, which also increases manufacturing time and cost.
Innovation Solution
A thin coating layer with a metal, less than 0.1 μm thick or 10% of the abrasive grain's mass, is applied to the super abrasive grains to control current flow during electrodeposition, preventing excess deposition and ensuring a uniform single layer of abrasive grains on the wire tool.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a thick coating layer is applied to super abrasive grains to increase electrodeposition rate, then the electrodeposition efficiency is improved, but excessive abrasive grains are electrodeposited which fall off and shorten tool life
Solution Approach 1:
The patent applies a thin coating layer (less than 0.1 μm thick or less than 10% of abrasive grain mass) instead of a thick coating layer. This parameter change in coating thickness optimizes the electrodeposition process by providing sufficient conductivity for efficient deposition while preventing excessive grain accumulation and fallout, thereby resolving the contradiction between productivity and reliability
Solution Approach 2:
The patent uses a coating layer that is thin enough to prevent excessive electrodeposition of abrasive grains. By controlling the coating thickness to be partial (just sufficient for conductivity) rather than excessive, the patent avoids the problem of grain fallout while maintaining adequate electrodeposition rate
2Productivity
If a thick coating layer is applied to super abrasive grains, then electrodeposition efficiency increases, but manufacturing time increases due to excess grain removal treatment
Solution Approach 1:
By changing the coating thickness parameter to less than 0.1 μm, the patent eliminates the need for subsequent excess grain removal treatments. This thin coating parameter achieves optimal electrodeposition efficiency without creating excessive grain deposition, thereby reducing total manufacturing time
Solution Approach 2:
The patent extracts the harmful effect of excessive grain deposition by using a thin coating layer that prevents over-deposition from occurring in the first place. This eliminates the need for the separate grain removal step, reducing manufacturing time
3Productivity
If a thick coating layer is applied to super abrasive grains, then electrodeposition rate increases, but abrasive grains are wasted due to excess deposition and fallout
Solution Approach 1:
The patent optimizes the coating layer thickness parameter to less than 0.1 μm, which prevents excessive abrasive grain deposition and subsequent fallout. This parameter optimization ensures that abrasive grains are deposited efficiently without being wasted, resolving the contradiction between productivity and substance loss
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 minimizes excess abrasive grain deposition, prolongs tool life, reduces manufacturing costs by eliminating the need for excess grain removal, and enhances electrodeposition efficiency by using only the necessary current.
Implementation Method 1
super abrasive grains have been adhered to the outer peripheral face of a long thin object that serves as a core wire by electrodeposition
Data Source
AI summary
A plating layer 18 of Ni or the like is formed around the outer peripheral face 14 of a wire tool 10, and super abrasive grains 16 are electrodeposited so as to be embedded in the plating layer 18. A coating layer 20 is formed on the surface of the super abrasive grains 16 to increase efficiency during electrodeposition. The thickness of the coating layer 20 formed on the super abrasive grains 16 is less than 0.1 μm, and preferably not more than 0.05 μm. The coating layer 20 is thin enough that its mass is less than 10% of the mass of the super abrasive grain 16. Accordingly, the super abrasive grains 16 are electrodeposited in a single layer around the outer peripheral face 14 of the core wire 12. As a result, the super abrasive grains 16 do not readily come off the core wire 12, which means that the wire tool will have a longer life. Also, since there is no need to remove any excess super abrasive grains after their electrodeposition, manufacturing costs can be cut and less work is entailed.