Extruded Composite Abrasive Particles for Durable Material Removal
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing abrasive technologies fail to produce composite shaped abrasive particles with optimal geometries and bonding capabilities for efficient material removal operations.
Innovation Solution
A method involving the formation of a ceramic-based mixture with controlled rheological properties, which is extruded through a screen to create precursor particles, followed by attachment of abrasive particles to the surface, and subsequent sintering to form composite shaped abrasive particles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional abrasive particles are used, then material removal operations can be performed, but the efficiency and durability are insufficient
Solution Approach 1:
The patent employs composite materials by combining a shaped body (such as a triangle, rectangle, or other geometric shapes) with multiple abrasive particles bonded to its surface. This composite structure integrates the geometric precision of the shaped body with the cutting capability of the abrasive particles, achieving both improved material removal efficiency and enhanced durability. The shaped body provides structural stability and optimal geometry for material removal, while the bonded abrasive particles ensure sustained cutting performance.
2Reliability
If abrasive particles are bonded to the surface, then durability is improved, but the bonding process complexity increases
Solution Approach 1:
The patent utilizes parameter changes by controlling the rheological properties of the mixture during the bonding process. By adjusting parameters such as viscosity, solid content, and mixing speed, the process achieves effective bonding of abrasive particles to the shaped body without requiring overly complex equipment or multi-step procedures. The mixture's rheological characteristics are optimized to ensure proper particle adhesion while maintaining process simplicity.
3Ease of manufacture
If a mixture with controlled rheological properties is used, then bonding capability is improved, but the manufacturing process complexity increases
Solution Approach 1:
The patent applies parameter changes by carefully controlling the rheological properties of the mixture, including viscosity, solid content percentage, and flow characteristics. These parameter adjustments enable the mixture to be extruded through screens effectively and allow abrasive particles to bond properly to the shaped body. By optimizing these parameters, the manufacturing process achieves good bonding capability without requiring excessively complex equipment or multi-stage processing.
Solution Approach 2:
The patent employs preliminary action by pre-forming the shaped body with optimal geometry before bonding abrasive particles to it. The shaped body is created in advance with dimensions and surface characteristics that facilitate subsequent particle attachment. This preliminary shaping step simplifies the overall manufacturing process by establishing the structural foundation before the bonding operation, reducing the need for complex post-processing.
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 produces abrasive particles with improved performance in terms of material removal efficiency and durability, enhancing grinding and polishing processes.
Implementation Method 1
the mixture is extruded through a screen to create precursor particles
Implementation Method 2
attachment of abrasive particles to the surface
Implementation Method 3
subsequent sintering to form composite shaped abrasive particles
Data Source
AI summary
An abrasive particle including a shaped abrasive particle including a body having a plurality of abrasive particles bonded to at least one surface of the body of the shaped abrasive particle.