Grinding Element Manufacturing via Profile Squeezing and Adhesive Bonding
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Solution Overview
Problem
Existing manufacturing methods for grinding elements in rotating grinding or polishing tools face challenges in producing endless lengths that can be easily cut to specific lengths, as cutting profiles with abrasive cloth results in significant wear on cutting tools.
Innovation Solution
A method involving a plane metal band with a longitudinal glue bead, where abrasive cloth and stiffening brushes are applied and folded into a U-shaped profile, with a retainer wire securing the brushes between the profile's side walls and bottom, allowing for continuous production and subsequent cutting into desired lengths without excessive tool wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If grinding elements are manufactured in endless lengths and then cut to specific lengths, then productivity and manufacturing efficiency are improved, but the abrasive cloth causes significant wear on cutting tools
Solution Approach 1:
The abrasive cloth is extracted and removed from the ends of the profile before cutting. This allows the profile to be cut without the abrasive material causing wear on cutting tools, while still maintaining the endless configuration for continuous manufacturing
Solution Approach 2:
The endless abrasive cloth is segmented by removing end portions, creating discrete sections that can be individually handled and attached to profile segments. This segmentation enables cutting of the profile without abrasive wear while preserving the continuous manufacturing capability
2Strength
If the profile is squeezed to secure abrasive cloth and brushes, then the attachment strength is improved, but the manufacturing complexity increases
Solution Approach 1:
The profile design merges the securing function into the profile structure itself through the undercut geometry. The squeezing action during manufacturing simultaneously forms the profile shape and secures the abrasive cloth and brushes, eliminating the need for separate securing mechanisms
Solution Approach 2:
The profile is pre-formed with undercut geometry that anticipates the squeezing operation. This preliminary design ensures that when the profile is squeezed during manufacturing, the abrasive cloth and brushes are automatically secured without requiring additional steps or complex equipment
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 the efficient manufacture of grinding elements in endless lengths, facilitating easy cutting to specific lengths while minimizing tool wear, ensuring secure attachment of abrasive cloth and brushes through gluing and mechanical squeezing.
Implementation Method 1
an adhesive means are continuously advanced to and through a mounting step and a fixing step
Implementation Method 2
the profile is statically deformed by the free edge regions of the two legs being pressed against each other, in order to narrow the opening and squeeze around and secure the abrasive cloth and the brushes
Data Source
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AI summary
Method for manufacturing an abrasive element for use in a rotary grinding or polishing tool, where abrasive cloth and brushes attached to a U-shaped profile where the two legs from the side walls around the abrasive element, the method is applied to a longitudinal glue bead on the U-profiles side wall, applying abrasive cloth against the glue bead, folding metal band to the U-shaped profile, placing the bristles against the opening of the profile, placing of a retainer wire against the pro-file opening, inserting the retainer wire in the profile between the side walls and bottom, then pressed leg free edge regions together against each other to fixing brushes, abrasive cloth and profile together.