Multicellular Foam Glass Abrasive Tool
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Solution Overview
Problem
Abrasives on a base experience wear due to decreasing sharpness, leading to reduced service life and inefficient machining processes, particularly in industrial applications where maintaining a defined surface structure and roughness is crucial.
Innovation Solution
A multicellular foam glass base body with abrasive grains attached using a binder, allowing for continuous vertical removal of unused grains and minimizing heat generation, while avoiding the drawbacks of hollow spheres such as premature opening and chip accumulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If multiple layers of bonding agent and abrasive grain are applied to a substrate, then the service life of the grinding tool is extended, but the surface area bearing capacity increases leading to heat generation and chip space compaction
Solution Approach 1:
The patent applies a porous bonding agent layer instead of dense multiple layers. The porous structure provides chip spaces that prevent compaction of abrasive particles, allowing continuous material removal without excessive heat generation while maintaining extended service life through the layered structure
2Area of stationary object
If a flat surface structure is created with multiple layers of abrasive grain, then the bearing area is increased, but chip spaces are reduced leading to compaction of abrasive particles and clogging
Solution Approach 1:
The bonding agent is formulated with a porous structure that maintains open chip spaces throughout the layered abrasive structure. This allows the bearing area to be increased through multiple layers while preventing chip compaction and clogging by providing continuous pathways for chip evacuation
3Area of stationary object
If hollow spheres are used as the base body, then the bearing area remains constant throughout operation, but the spheres open prematurely and accumulate chips leading to surface defects
Solution Approach 1:
The patent uses a porous bonding agent structure instead of hollow spheres. This provides continuous chip spaces that prevent chip accumulation and surface defects while maintaining consistent bearing area throughout operation, eliminating the premature opening problem of hollow spheres
4Reliability
If the abrasive grain is removed continuously to maintain sharpness, then the cutting edge geometry is maintained, but the service life is reduced due to frequent tool changes
Solution Approach 1:
The patent applies abrasive grains in multiple layers with porous bonding agent, creating local chip spaces that allow continuous material removal while maintaining cutting edge sharpness. This extends service life by preventing the rapid dulling that occurs with single-layer structures, reducing the frequency of tool changes
Data Source
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AI summary
Abrasive comprises a base body and abrasive particles applied to the surface of the base body, where the base body has a multicellular structure. Independent claims are also included for: (1) producing an abrasive, comprising providing the multicellular base bodies, coating the base body with binder, and coating the base body with abrasive particles; (2) a grinding tool comprising a substrate, a binder for abrasive, and an abrasive, where the substrate comprises a woven fabric, a knitted fabric or paper, film or nonwoven; and (3) a bonded grinding tool, comprising binder and abrasive.