Grinding Tool with Obliquely Truncated Pyramid Abrasive Particles
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Solution Overview
Problem
Conventional grinding tools used in chemical mechanical polishing techniques face challenges in maintaining optimal grinding efficiency over time, requiring increased abrasive element distribution which increases manufacturing costs and diminishes cutting rate.
Innovation Solution
A grinding tool with a substrate and abrasive particles machined to form obliquely truncated pyramid shapes, distributed to protrude outward, enhancing cutting rate and wear resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the distribution density of abrasive elements is increased to improve cutting rate, then the cutting rate is improved, but the manufacturing cost increases
Solution Approach 1:
The patent applies local quality by creating asymmetric abrasive particles with a unidirectional bevelled surface. This asymmetric geometry concentrates the cutting action on one primary edge, making each abrasive particle more effective at cutting. The bevelled surface is formed by selective machining that creates different surface qualities on different faces of the abrasive particle, with one face having a sharp cutting edge and other faces having varying degrees of dullness, thereby improving cutting performance without increasing quantity
Solution Approach 2:
The patent changes the geometric parameters of abrasive particles by introducing a specific bevel angle (α) ranging from 10° to 45°. This parameter modification transforms conventional symmetric abrasive particles into asymmetric ones with optimized cutting edges. The controlled beveling process alters the surface topology and edge sharpness parameters, enabling each particle to maintain effective cutting geometry for longer periods, thus improving productivity without proportionally increasing manufacturing cost
2Reliability
If the distribution density of abrasive elements is increased to maintain grinding efficiency, then the grinding efficiency is maintained, but the manufacturing complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the abrasive particle into distinct functional zones through selective beveling. Each particle is segmented into a primary cutting face with a sharp edge, secondary faces with intermediate dullness, and a base face. This segmentation of functional zones within each particle allows for optimized cutting performance while using a standard abrasive material, avoiding the need for complex multi-component structures
Solution Approach 2:
The patent applies preliminary action by pre-machining the abrasive particles to create asymmetric bevelled surfaces before they are applied to the workpiece. The beveling process is performed in advance during abrasive particle fabrication, creating ready-to-cut geometric features that will function optimally during the grinding operation. This preliminary geometric conditioning ensures consistent cutting performance without requiring complex real-time adjustments during manufacturing assembly
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 tool achieves improved cutting rates and surface roughness, maintaining grinding efficiency while being cost-effective by using machined abrasive particles, outperforming conventional tools without machined surfaces.
Implementation Method 1
Grinding and/or polishing techniques are generally applied to create a desirable surface roughness or planarity on a rigid part... the grinding and/or polishing techniques use tools having abrasive elements that can wear the hard surface
Data Source
AI summary
A grinding tool includes a substrate having a working surface, and a plurality of abrasive particles distributed over the working surface and protruding outward from the working surface, wherein at least some of the abrasive particles are machined to form abrasive particles respectively having an obliquely truncated pyramid shape. Some embodiments described herein also include a method of manufacturing the grinding tool.