Grinding Wheel With Metal Foil And Elastomeric Layer
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Solution Overview
Problem
Existing grinding wheels for reworking resistance welding electrodes face issues with short service life due to wear, producing impermissible deep channels or grooves, and fail to effectively dampen shocks and vibrations, leading to loud operation and mechanical stress on the grinding apparatus.
Innovation Solution
A grinding wheel with an elastically deformable metal foil bonded to an elastomeric supporting layer, where abrasive particles are galvanically bonded to protrude 30-50% from the metal surface, providing a hard yet flexible grinding surface that reduces vibration and noise during operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If a solid metal disk with galvanically bonded diamond particles is used, then service life is improved, but flexibility is lost causing loud operation and mechanical stress
Solution Approach 1:
The patent applies this principle by bonding a metal foil layer with abrasive particles to a flexible supporting layer, creating a grinding wheel that combines the hardness and wear resistance of metal with the flexibility and vibration-dampening properties of the elastomeric supporting layer, thereby reducing noise and mechanical stress while maintaining service life
Solution Approach 2:
The patent applies this principle by creating a composite structure consisting of a metal foil layer with galvanically bonded abrasive particles (such as diamond) combined with an elastomeric supporting layer, merging the advantages of both materials: the hardness and durability of metal with the flexibility and shock-absorbing properties of elastomers
2Object-affected harmful factors
If conventional grinding wheels are used, then flexibility is maintained, but service life is reduced due to wear and channel formation
Solution Approach 1:
The patent applies this principle by creating a composite structure where a metal foil layer with galvanically bonded abrasive particles provides enhanced wear resistance and service life, while the elastomeric supporting layer maintains flexibility, effectively combining the advantages of both material types to overcome the limitations of conventional single-material grinding wheels
Solution Approach 2:
The patent applies this principle by using a thin metal foil layer bonded to a flexible elastomeric supporting layer, maintaining the flexibility needed for effective grinding while the metal foil with abrasive particles provides the durability and resistance to channel formation that limits service life of conventional flexible grinding wheels
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 solution results in a grinding wheel with a high service life, high material removal rate, and a low-vibration grinding process, minimizing the production of grinding dust and reducing mechanical stress on the apparatus, while maintaining stability comparable to solid metal wheels.
Implementation Method 1
abrasive particles are galvanically bonded to protrude 30-50% from the metal surface
Implementation Method 2
grinding wheel with an elastically deformable metal foil bonded to an elastomeric supporting layer, where abrasive particles are galvanically bonded
Implementation Method 3
elastically deformable metal foil which is fastened directly on an elastomeric deformable supporting layer
Implementation Method 4
providing a hard yet flexible grinding surface that reduces vibration and noise during operation
Data Source
AI summary
A grinding wheel includes an elastomerically deformable supporting layer, at least a first metallic surface fastened to the elastomerically deformable supporting layer, the metalic surface being an elastically deformable metal foil and includes abrasive particles attached to the at least one metalic surface. The particles may include at least one of: cubic boron nitride or diamonds. The metal foil may have a thickness of less than 1 mm. The abrasive particles may be bonded galvanically on the metallic surface. The abrasive particles may be bonded on the metalic surface in a plurality of areas having regions without abrasive particles therebetween. The metal foil may be adhesively bonded onto the elastomerically deformable supporting layer. The elastomerically deformable supporting layer may be plastic foam. The elastomerically deformable supporting layer may be adhesively bonded onto a metallic supporting body.