Grinding Tool Production Using Lattice Recesses for Diamond Particle Fixation
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Solution Overview
Problem
Existing methods for producing grinding tools with diamond particles face issues such as auxiliary grid influence on product quality, difficulties in separating and removing diamond particles due to varying orientations and sizes, and metal bed perforation and snagging during particle placement.
Innovation Solution
A lattice structure is created on the powdered matrix by forming recesses in the form of truncated cones or pyramids, allowing precise fixing of diamond particles and preventing metal bed displacement during pressing and layer application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If an auxiliary grid is used to separate diamond particles during placement, then particle positioning is improved, but product quality deteriorates due to grid influence and removal difficulties
Solution Approach 1:
The invention eliminates the auxiliary grid structure entirely, extracting the harmful element from the system. Instead of using a grid to separate particles, the method relies on the natural spacing and positioning of particles during the pressing process, allowing complete removal of the grid-related harmful influences from the final product.
Solution Approach 2:
The invention introduces a liquid medium as an intermediary substance between the diamond particles and the metal matrix. This liquid facilitates uniform particle distribution and positioning during pressing, replacing the need for a physical grid structure while avoiding the harmful effects of grid presence in the final product.
2Manufacturing precision
If diamond particles are placed using a perforated plate with pins, then particle separation is improved, but the metal bed suffers from perforation and snagging
Solution Approach 1:
The invention removes the perforated plate structure from the process, extracting the source of mechanical damage to the metal bed. Particle separation and placement are achieved through the liquid medium and controlled pressing, eliminating perforation and snagging of the metal bed.
Solution Approach 2:
The invention replaces the mechanical pin-ejection system with a liquid-mediated placement system. Instead of using pins to physically eject and position particles, the liquid medium carries and deposits particles in their final positions, eliminating mechanical contact that causes metal bed damage.
3Manufacturing precision
If diamond particles are deeply pressed into a flat base, then particle fixation is improved, but metal bed displacement and loosening occurs
Solution Approach 1:
The invention creates recesses in the metal matrix before placing the diamond particles. This preliminary action prepares the structure to receive particles without requiring deep pressing, thus fixing particles securely while maintaining the stability of the surrounding metal bed structure.
Solution Approach 2:
The invention uses curved or conical recesses instead of flat surfaces. The curved geometry of the recesses provides better particle retention through geometric confinement, allowing shallow placement that doesn't disrupt the metal bed structure, unlike deep pressing into flat bases.
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
Ensures precise positioning and clear layer assignment of diamond particles, preventing metal bed displacement and improving product quality by using a self-formed lattice structure on the matrix, which enhances the uniform arrangement and retention of diamond particles.
Implementation Method 1
A negative pressure is maintained in the interior 9 of the perforated plate 1, which pressure propagates to the mouths of the bores 6, so that a grain 4 is held there in each case.
Implementation Method 2
The holes 6 in the perforated plate 1 have a larger diameter (approx. 0.6 mm) than the average grain size, so that the grains 4 can settle therein. A typical distance between the holes 6 is 1.25 mm. How out Figures 1 and 2 results, a first function of the pins 3 is to prevent clogging of the holes 6 by smaller grains.
Implementation Method 3
If the recesses are in the form of truncated cones or pyramids, the diamond particles are precisely fixed and remain in their position both when the powder is pressed and in particular when a further layer is applied and pressed
Data Source
Figure 1~3
Figure 4~6
AI summary
The invention relates to a method for producing a grinding tool comprising diamond particles disposed at a distance from each other, wherein recesses are formed on the surface of a powdery sinterable matrix recess by pressing a pattern into the powdery matrix, a diamond particle being placed into each recess before the matrix containing the diamonds is pressed and finally sintered.