Grinding Tool Laser Cutting Soot Evacuation
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Solution Overview
Problem
Existing methods for manufacturing grinding tools with binding agents generate soot particles during the cutting process, leading to contamination and increased cleaning efforts, as well as potential user safety hazards from sharp edges and web tension influences on the outer contour.
Innovation Solution
A method involving a laser device to cut inner and outer contours of grinding tools with a binding agent based on aromatic molecules, where soot particles are evacuated using a gas volume flow, and the outer contour is punched out from an abrasive material parent web with rounded edges to prevent contamination and edge deformation, utilizing a cutting board with underpressure fixation and a soot evacuation device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If laser cutting is used to cut contours of grinding tools with urea-based binding agent, then cutting precision is improved, but soot particle generation increases causing contamination
Solution Approach 1:
The patent applies this principle by using the laser's thermal energy, which normally causes soot generation as a harmful side effect, to effectively cut through the abrasive material parent web and binding agent. The laser cutting process is optimized to achieve precise contours while the soot particles are managed through evacuation systems, converting the potentially harmful thermal effect into a useful cutting mechanism.
Solution Approach 2:
The patent introduces an intermediary evacuation system that captures and removes soot particles generated during laser cutting. This intermediary system acts as a mediator between the laser cutting process and the surrounding environment, preventing soot contamination while maintaining the benefits of laser cutting precision.
2Object-generated harmful factors
If outer contour is punched out from abrasive material parent web, then soot particle deposition is reduced, but edge sharpness may be compromised
Solution Approach 1:
The patent applies segmentation by dividing the contour cutting process into two distinct stages: inner contours are cut by laser with high precision, while the outer contour is punched out to define the final shape and size. This segmentation allows each process to optimize for its specific function, with punching providing clean edges without soot contamination.
Solution Approach 2:
The patent changes the processing parameters and methods for different contours: laser parameters are optimized for precise inner contour cutting, while punching parameters (knife geometry, pressure, speed) are optimized for clean outer contour separation with smooth edges, avoiding both soot deposition and edge deformation.
3Strength
If binding agent based on aromatic molecules is used, then binding strength is improved, but soot particle formation increases during laser cutting
Solution Approach 1:
The patent utilizes the aromatic binding agent's properties, which provide strong binding strength for holding abrasive grains, while accepting that laser cutting of this material generates soot. The harm is converted to benefit by implementing an evacuation system that captures the soot, allowing the use of superior binding agents without the penalty of contamination.
Solution Approach 2:
An intermediary evacuation system is introduced to capture and remove soot particles generated during laser cutting of the aromatic binding agent. This mediator prevents the soot from contaminating the grinding tool and surrounding area, enabling the use of high-performance aromatic binding agents.
4Manufacturing precision
If laser device cuts inner contours, then manufacturing precision is improved, but cleaning efforts and costs increase due to soot contamination
Solution Approach 1:
The patent applies preliminary action by implementing a soot evacuation system that operates during the laser cutting process itself, capturing and removing soot particles before they can deposit on the grinding tool. This preliminary removal action prevents contamination rather than addressing it after the fact, eliminating the need for subsequent cleaning operations.
Solution Approach 2:
The patent converts the harmful soot generation inherent in laser cutting into a manageable byproduct by implementing evacuation systems. This allows the precision benefits of laser cutting to be fully realized while the soot is continuously removed, transforming a cleaning burden into a controlled process parameter.
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
Significantly reduces soot particle deposition on the grinding tool, minimizes cleaning costs, prevents user contamination, and ensures smooth edges and accurate punching by evacuating soot particles effectively and avoiding web tension influences.
Implementation Method 1
at least one inner contour of the grinding tool is cut by means of a laser device
Implementation Method 2
the contour of the grinding tool is generated by burning a shape out of a blank, in particular the abrasive material parent web, using the power of a laser
Implementation Method 3
wherein soot particles formed in a cutting process of the inner contour and the outer contour are extensively evacuated
Implementation Method 4
an outer contour of the grinding tool is punched out of an abrasive material parent web
Data Source
AI summary
A method for manufacturing a grinding tool which has a binding agent based on aromatic molecules includes cutting an abrasive material parent web with a laser device to form at least one inner contour of the grinding tool, and punching out an outer contour of the grinding tool from the abrasive material parent web.