Grinding Wheel Arbor Mounting for Runout Reduction

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Solution Overview

Problem

Existing metal-bonded grinding wheels face issues with time-consuming coupling and uncoupling processes, leading to deformation and dimensional inaccuracies, which increase the likelihood of runout and reduce their limited lifespan, thereby increasing machining operation costs and time.

Innovation Solution

A method and system where a grinding wheel with a ring-structure formed from grit particles dispersed in metallic material is mounted on an arbor with a gear and bearing system, allowing it to be dressed and used as a unitary assembly across different machines, reducing runout and extending its service life by maintaining stability and enabling immediate use after conditioning.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the grinding wheel is repeatedly coupled and uncoupled from different shafts in different machines, then the grinding wheel can be processed and mounted, but deformations and dimensional inaccuracies occur leading to runout

Engineering Contradiction:

Improvegrinding wheel processing and mountingVSAvoiddimensional accuracy and runout

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The process is segmented into distinct stages: first mounting the grinding wheel on the arbor in the plating vessel for abrasive material deposition, then keeping it mounted during truing and dressing operations. This segmentation allows each operation to be performed on the assembled unit without repeated disassembly and reassembly, eliminating the cumulative deformations that would otherwise occur.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The grinding wheel is preliminarily mounted on the arbor with the gear and bearing system before undergoing truing and dressing operations. This preliminary assembly establishes a stable reference frame that prevents dimensional inaccuracies during subsequent processing, ensuring the final profile is achieved with high precision relative to the arbor mounting axis.

Inventive Principle:

Principle #10Preliminary action

2Ease of manufacture

If the grinding wheel has a short and limited lifespan, then the initial cost may be lower, but the cost and time needed to perform machining operations increases

Engineering Contradiction:

Improvegrinding wheel initial costVSAvoidmachining operation efficiency

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

Instead of discarding the grinding wheel after limited use, the system enables recovery and reuse by maintaining the wheel on the arbor for multiple conditioning cycles. The stable mounting and precise dressing process restore the wheel's cutting edges and profile, extending its service life and allowing it to be reused across multiple machining operations without realignment or remounting.

Inventive Principle:

Principle #34Discarding and recovering

Solution Approach 2:

The truing and dressing operations apply partial removal of material to restore the grinding wheel's surface profile and remove worn sections. This partial action rejuvenates the wheel's cutting capability without requiring complete replacement, effectively extending its operational lifespan while maintaining machining quality.

Inventive Principle:

Principle #16Partial or excessive action

3Adaptability or versatility

If the grinding wheel is mounted and processed in multiple separate machines, then each operation can be specialized, but the process becomes time-consuming

Engineering Contradiction:

Improvespecialized processing operationsVSAvoidcoupling and uncoupling time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

Multiple processing operations—mounting, abrasive material deposition, truing, and dressing—are merged into a single integrated workflow where the grinding wheel remains mounted on the arbor throughout. This eliminates the time-consuming coupling and uncoupling steps between machines while maintaining the specialized capabilities of each operation through sequential processing of the same assembled unit.

Inventive Principle:

Principle #5Merging (Combining)

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

This approach enhances the surface finish of the grinding wheel, reduces rotational runout, and extends the grinding wheel's service life by allowing it to be reconditioned and used as a fully assembled structure across various machines, improving machining efficiency and reducing operational costs.

Implementation Method 1

using an acoustic sensor to determine when contact is achieved between the dressing tool and the grinding wheel

Methodology Applied

Scientific EffectAcoustic sensing: Acoustic Emission

Data Source

PatentUS11577365B2Systems and methods of processing a rotatable assembly

Publication Date: 2023.02.14 HONDA MOTOR CO LTD

AI summary

A method of processing a rotatable assembly is described herein. The method includes mounting a grinding wheel on an arbor to form the rotatable assembly. The grinding wheel has a ring-structure formed from a plurality of grit particles dispersed within a metallic material. The method also includes mounting the rotatable assembly within at least one dressing machine, wherein the rotatable assembly is rotatable relative to a dressing tool within the at least one dressing machine, and shaping the grinding wheel with the dressing tool to define a final outer profile of the grinding wheel configured to machine a workpiece.