Metal-Bonded Grinding Wheel Surface Structuring to Prevent Smearing
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Solution Overview
Problem
Conventional metal-bonded grinding wheels are not suitable for machining graphite, graphite-containing materials, hardened steels with a hardness of 30-66 HRC, plastics, or abrasive composite materials due to smearing issues caused by inadequate chip spaces and low grip.
Innovation Solution
A grinding tool with ultra-hard grains bonded in a metallic matrix, where the matrix is selectively removed using a spark erosion or laser process to expose at least 30% of the grains by 40% or more of their size, creating chip spaces and improving grip and wear resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If ultra-hard grains are completely enclosed in the metallic bond matrix to achieve high wear resistance, then the service life is extended, but the grip and chip space are insufficient causing smearing during machining
Solution Approach 1:
The invention applies different properties to different regions of the grinding wheel. The bond matrix is removed selectively at specific locations between ultra-hard grains to create localized chip spaces, while maintaining the intact bond structure in other areas to preserve grain retention and wear resistance. This local modification resolves the contradiction by providing both grip (through exposed grains) and wear resistance (through retained grains in intact bond).
Solution Approach 2:
The grinding wheel surface is segmented into multiple functional zones: regions where the bond matrix is removed to expose grains for machining, and regions where grains remain enclosed for wear resistance. This segmentation allows different portions of the grinding wheel to perform different functions simultaneously, resolving the contradiction between grip and service life.
2Adaptability or versatility
If conventional grinding wheels are used for machining graphite and hardened steels, then general machining is possible, but smearing occurs due to inadequate chip spaces
Solution Approach 1:
The invention creates localized chip spaces by selectively removing the bond matrix in specific regions between ultra-hard grains. These localized modifications provide adequate chip spaces for machining graphite and hardened steels without affecting the overall structural integrity and grain retention of the grinding wheel, thereby preventing smearing while maintaining versatility.
3Reliability
If the bond matrix is removed to expose grains for better grip, then chip spaces are created, but wear resistance may be reduced
Solution Approach 1:
The bond matrix is removed only in specific localized regions between ultra-hard grains, not uniformly across the entire surface. This selective removal creates chip spaces and exposes grains for improved grip in necessary areas, while leaving the bond matrix intact in other areas to maintain grain retention and wear resistance.
Solution Approach 2:
The grinding wheel is divided into functional segments: exposed grain regions for machining and retained grain regions for wear resistance. This segmentation allows the system to achieve both good grip (through exposed grains) and wear resistance (through retained grains) simultaneously.
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 tool achieves high grip and wear resistance, preventing smearing during machining of challenging materials by allowing the exposed grains to bite into the material and forming effective chip spaces.
Implementation Method 1
the matrix is selectively removed using a spark erosion or laser process to expose at least 30% of the grains by 40% or more of their size
Implementation Method 2
the matrix is selectively removed using a spark erosion or laser process to expose at least 30% of the grains by 40% or more of their size
Data Source
Figure 1a~3
AI summary
The invention relates to a grinding tool, a method for manufacturing such a tool, and a use of the grinding tool. The grinding tool comprises a base body to which ultra-hard grains (16) of at least one grain size X are bonded by a metallic bonding matrix (14) to form a grinding surface (18), wherein at least the grinding or deburring surface (18) is processed before initial use and then, if burn-off is present, after its removal, by means of a spot-acting ablation process in the form of a spark erosion or laser process, wherein the bonding matrix (14) is ablated by the ablation process to such an extent that, after ablation, at least 30% of the ultra-hard grains protruding from the bonding matrix are exposed with a protrusion Ü of at least 40% relative to the grain size X in the direction R perpendicular to the grinding or deburring surface (18).The grinding tool is particularly suitable for machining graphite, graphite-containing material or at least a material from the group of hardened steels with a hardness in the range of 30 to 66 HRC (HRC = Rockwell hardness), plastics and/or abrasive composite materials.