Grinding Element with Active Materials for Temperature Control
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Solution Overview
Problem
Existing grinding elements lack effective means to adapt and improve machining properties such as temperature control, hardness, and durability, particularly when processing hard metals, leading to inefficiencies in material removal and potential clogging from abrasive dust.
Innovation Solution
A grinding element with a ceramic base material, incorporating additional active materials like avogadrite for cooling and tungsten carbide for increased hardness, which are bonded to the base material and distributed uniformly, allowing for targeted adjustment of operating parameters through heating and sintering processes, enhancing machining performance and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional grinding elements are used, then basic grinding function is provided, but temperature control and machining properties cannot be effectively adapted
Solution Approach 1:
The grinding element uses a composite base body made by mixing ceramic base material (corundum) with additional active materials (avogadrite for cooling, tungsten carbide for hardness). This composite structure enables multiple functions (grinding, cooling, hardening) within a single integrated component, improving adaptability without proportionally increasing complexity
Solution Approach 2:
The additional active materials are distributed over at least part of the base body, with preferred uniform distribution. This allows different regions of the grinding element to have tailored properties - for example, concentrating cooling material in high-heat zones or hardening material at the grinding surface, enabling localized optimization of machining properties
2Productivity
If grinding elements process hard metals, then material removal is achieved, but temperature increases and clogging from abrasive dust occurs
Solution Approach 1:
Avogadrite ((K,Cs)BF4) is incorporated as an additional active material that undergoes phase transition (melting) at relatively low temperatures during grinding operations. This phase change absorbs large amounts of heat (latent heat of fusion), providing active cooling of the grinding element and workpiece interface, thereby controlling operating temperature while maintaining material removal efficiency
Solution Approach 2:
The additional active materials act as intermediary substances between the base material and the external environment. Avogadrite mediates heat transfer through phase transition, while tungsten carbide mediates mechanical stress and wear. These intermediaries protect the base corundum structure while enabling controlled temperature and improved machining performance
3Reliability
If base material is mixed with additional active material, then machining properties are improved, but manufacturing process becomes more complex
Solution Approach 1:
The manufacturing process controls the mixing ratio and particle size distribution of the ceramic base material and additional active materials. By optimizing these parameters (concentration, particle size, distribution uniformity), the patent achieves reliable durability improvements while keeping the manufacturing process manageable through standard ceramic processing techniques like mixing, forming, and sintering
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 grinding element achieves improved machining efficiency for hard metals, effective cooling, and reduced clogging, resulting in a stable and long-lasting grinding tool with enhanced machining capabilities.
Implementation Method 1
The additional active material is preferably activated in an operating state, in particular by heating the grinding element, for example by melting
Implementation Method 2
avogadrite for cooling in an operating state
Implementation Method 3
tungsten carbide to increase the hardness of the base body. Tungsten carbide has the chemical formula WC. Tungsten carbide is one of the non-oxidic ceramics and has a hardness of in particular at least 2000 HV
Implementation Method 4
The at least one additional active material is at least partially bonded to the base material. 'Materially connected' is to be understood in particular as meaning that the mass parts are held together by atomic or molecular forces
Implementation Method 5
a method for producing a grinding element according to the invention with at least a first step in which a base material is mixed with at least one additional active material and with at least one further step in which a base body is formed from the base material and the at least one additional active material... which includes a sintering method
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to a grinding element (10, 110, 210) with a main part (12, 112, 212) which comprises at least one base material (14, 114, 214). The main part (12, 112, 212) comprises at least one additional active material (16, 116, 216) which is provided in order to at least partly influence at least one machining parameter at least in an operating state.