Grinding Wheel Laser Surface Feature Modification

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional dressing techniques for grinding wheels are inefficient in modifying and adding features to reduce radial contact, spindle power consumption, and heat input while enhancing coolant delivery and chip evacuation.

Innovation Solution

A method involving a laser directed substantially perpendicular to the grinding wheel surface, pulsed to ablate material and form surface features, which can be steered to create specific patterns for improved coolant delivery and reduced power consumption.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by stationary object

If conventional dressing techniques are used, then the grinding wheel surface can be maintained, but the ability to modify and add features to reduce radial contact, spindle power consumption, and heat input is insufficient

Engineering Contradiction:

Improvespindle power consumptionVSAvoiddifficulty of adding surface features

Core Design Contradiction:

Use of energy by stationary objectVSEase of manufacture

Solution Approach 1:

The patent replaces conventional mechanical dressing techniques with a laser-based system. The laser ablates the grinding wheel surface to create features without mechanical contact, enabling precise control over feature geometry and distribution. This substitution allows for adding surface features that reduce radial contact and power consumption while avoiding the limitations of mechanical dressing tools.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The laser system enables dynamic control of surface feature parameters including depth, width, spacing, and distribution patterns. By adjusting laser pulse duration, energy density, and scanning patterns, the system can create optimized features that minimize radial contact area and reduce spindle power requirements while maintaining grinding wheel functionality.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If the grinding wheel runs at high speed, then material removal efficiency is improved, but heat input and overheating increase

Engineering Contradiction:

Improvematerial removal efficiencyVSAvoidheat input

Core Design Contradiction:

ProductivityVSTemperature

Solution Approach 1:

The laser creates a porous or textured surface structure on the grinding wheel with controlled voids and channels. This porous structure reduces the actual contact area between the grinding wheel and workpiece, thereby reducing heat generation during high-speed grinding while maintaining material removal efficiency through the preserved abrasive grain distribution.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The laser pre-modifies the grinding wheel surface before grinding operations by creating features that optimize coolant flow paths and reduce contact area. This preliminary surface modification ensures that during high-speed grinding, less heat is generated at the contact interface, allowing sustained high productivity with controlled temperature rise.

Inventive Principle:

Principle #10Preliminary action

3Temperature

If coolant is applied to the grinding wheel, then overheating is minimized, but coolant delivery efficiency can be improved with surface features

Engineering Contradiction:

Improvecoolant effectivenessVSAvoidcoolant delivery enhancement

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The laser creates localized surface features at specific locations on the grinding wheel surface where coolant delivery is most needed. These features include channels, recesses, and textured areas that concentrate coolant flow at high-heat-generation zones, improving cooling effectiveness without requiring uniform modification of the entire wheel surface.

Inventive Principle:

Principle #3Local quality

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 laser-based method effectively enhances coolant delivery and reduces the horsepower required to drive the grinding wheel by creating surface features that decrease contact area and improve coolant application during grinding.

Implementation Method 1

laser ablating a first surface feature in a grinding wheel

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Data Source

PatentUS9895787B2Methods for modifying and adding features on grinding wheel surfaces

Publication Date: 2018.02.20 RTX CORP

AI summary

Systems and methods are disclosed herein for adding surface features to grinding wheels. A laser may be directed substantially perpendicular to a grinding surface of a grinding wheel. The laser may be pulsed and may ablate material from the grinding surface. The laser may move relative to the grinding wheel in order to ablate shaped surface features into the grinding surface.