Fan-Type Grinding Wheel With Bent Elements For Three-Face Roughing
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Solution Overview
Problem
Conventional fan-type grinding wheels are not designed for all-around use with high grinding performance, limiting their ability to efficiently machine heavy workpieces without rotating them or changing the grinder's position.
Innovation Solution
A fan-type grinding wheel with bent grinding elements forming semi-frustoconical shapes around the outer rim, allowing for overlapping and forming a peripheral working face, enabling three-face roughing without rotating the workpiece or changing the grinder's position, and a rigid support plate for absorbing high loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If grinding elements are disposed only around the outer peripheral rim in a conventional fan-type grinding wheel, then the structure is simple, but the grinding performance is limited and cannot achieve all-around use
Solution Approach 1:
The grinding elements are bent into a three-dimensional arc shape that extends radially outward from the support plate, creating a multi-dimensional grinding surface. This allows the grinding elements to form not only a planar working face on the support plate side but also a peripheral working face on the outer rim side, enabling three-face roughing capability for machining upper sides, undersides, and concave surfaces of workpieces
Solution Approach 2:
Each grinding element is divided into distinct functional portions: a main portion forming the planar grinding surface, a bending portion creating the arc shape, and an outer portion forming the peripheral grinding surface. This segmentation allows each portion to serve a specific grinding function, achieving versatile all-around use capability
2Adaptability or versatility
If grinding elements are bent into semi-frustoconical shapes to form peripheral working face, then three-face roughing is enabled, but the fastening complexity increases
Solution Approach 1:
The grinding elements are pre-bent into the desired arc shape with semi-frustoconical configuration before being mounted on the support plate. This preliminary shaping allows the elements to self-align and overlap neatly when fastened, simplifying the assembly process despite the complex three-dimensional geometry required for three-face roughing capability
Solution Approach 2:
The grinding elements are designed with specific geometric parameters including the arc radius, bending angle, and semi-frustoconical shape dimensions that optimize both the three-face roughing performance and the ease of fastening. These parameters are carefully selected to ensure the elements can be easily attached while maintaining the required structural integrity and grinding performance
3Productivity
If a rigid support plate is used to withstand high transverse grinding forces, then grinding performance is improved, but the weight of the grinding wheel increases
Solution Approach 1:
The support plate is constructed from composite materials or optimized material combinations that provide high rigidity and strength to withstand intense transverse grinding forces during three-face roughing operations, while minimizing the overall weight of the grinding wheel. This allows high productivity through effective machining of heavy workpieces without excessive weight increase
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
Enables efficient machining of heavy workpieces' upper and underside surfaces without rotation, maintaining rigidity to withstand high transverse grinding forces, and allowing for concave surface machining with improved grinding performance.
Implementation Method 1
The grinding elements are fastened - if necessary only locally - on the two working faces of the rim region of the support plate only in the region of the leading longitudinal edge
Data Source
AI summary
A fan-type grinding wheel comprises a rigid support plate and is provided with grinding elements. These grinding elements comprise a main portion forming a first working face and a bending portion forming a peripheral working face. Furthermore, they comprise an outer portion forming a second working face.