Grinding Wheel With Proportional Water Outlets
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Solution Overview
Problem
Current grinding wheels face inefficiencies in cooling and chip removal, leading to deformation and reduced processing quality and efficiency, particularly in special-shaped grinding applications, and the complex structure and high costs of inner cooling systems limit their effectiveness.
Innovation Solution
An anti-deforming and highly efficient grinding wheel design featuring a base with a grinding ring that includes multiple water outlets communicating with water channels and a water inlet, allowing for effective cooling and chip removal, adaptable to both inner and outer cooling systems, and capable of proportional entity processing regions to match machining allowances, reducing deformation and production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If inner cooling mechanism is implemented in grinding wheel, then cooling effect and chip removal are improved, but device complexity and production costs increase
Solution Approach 1:
The grinding wheel is divided into multiple functional zones with different abrasive grain densities along the axial direction. The first grinding face has a first abrasive grain density while the second grinding face has a second abrasive grain density, creating segmented functional regions that address different machining needs without requiring complex internal cooling structures
Solution Approach 2:
Different regions of the grinding wheel are given different local properties through varying abrasive grain densities. The first grinding face region has higher abrasive grain density for aggressive material removal, while the second grinding face region has lower abrasive grain density for finer finishing, allowing each region to optimize its function independently
2Device complexity
If conventional grinding wheel design is used, then device complexity is low, but chip removal efficiency and processing quality deteriorate
Solution Approach 1:
The grinding wheel operates dynamically by rotating at different speeds and utilizing centrifugal force to eject chips through the porous structure. The dynamic rotation creates varying pressure zones that facilitate chip evacuation through the abrasive layer without requiring complex mechanical chip removal mechanisms
Solution Approach 2:
The grinding wheel incorporates a porous structure within the abrasive layer that allows chips to pass through during rotation. This porous design enables passive chip removal through the grinding face itself, eliminating the need for complex external chip evacuation systems while maintaining structural simplicity
3Adaptability or versatility
If special-shaped grinding face is used, then machining versatility is improved, but deformation of grinding face occurs reducing service life
Solution Approach 1:
The grinding wheel uses a composite structure combining abrasive grains with a porous bonding matrix. This composite material design allows the special-shaped grinding face to maintain its geometry under stress while the porous structure provides flexibility to accommodate deformation without catastrophic failure, extending service life
Solution Approach 2:
Instead of trying to prevent deformation through rigid structural design, the invention accepts and accommodates deformation through the porous structure that can flex and adapt. The porous nature allows controlled deformation without compromising the overall special-shaped geometry or immediate functionality
4Temperature
If cooling water is applied externally, then cooling is provided, but chips form a proof layer preventing effective cooling and reducing efficiency
Solution Approach 1:
The cooling function is extracted from the external cooling system and integrated directly into the grinding wheel structure through the porous abrasive layer. Cooling water is delivered through channels within the grinding wheel body, allowing direct cooling at the grinding interface without chips interfering with water delivery
Solution Approach 2:
The porous abrasive layer acts as an intermediary medium that simultaneously performs grinding and chip evacuation functions. Chips pass through this porous layer while cooling water flows through the same structure, allowing both functions to occur without one interfering with the other
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 design enhances chip removal efficiency, maintains grinding wheel sharpness, and extends its service life by ensuring continuous cooling and proportional abrasion, allowing for high-quality processing without the need for expensive inner cooling systems, thus improving production efficiency and reducing costs.
Implementation Method 1
the coolant is fast separated from the processing face of the workpiece under the action of the centrifugal force due to the rotation of the grinding wheel
Implementation Method 2
A large amount of grinding heat and chips are produced in the grinding process of the grinding wheel
Data Source
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AI summary
Disclosed is a highly efficient cutting and grinding wheel designed to retain its shape, comprising a basic body (1) and a grinding ring (2), with water outlets (2-1) uniformly distributed on the grinding face of the grinding ring (2). Within the range of the length of the arc arbitrarily set on the grinding face, the number of the water outlets (2-1) is greater than zero, and the length of the arbitrarily set arc is 1-3 times the contact length between the grinding ring (2) and a workpiece being machined (8) when grinding. The grinding face is a heteromorphic grinding face and the outside of the water outlets (2-1) is an entity machining area of the heteromorphic grinding face that is involved in grinding. The overall line length of the circumference of the entity machining area in different axial positions corresponds to the machining allowance of the workpiece being machined (8) at the same positions and the correlation therebetween is directly proportional or nearly directly proportional. Water channels in communication with the water outlets (2-1) are made inside the basic body (1), cooling water being injected from a water inlet (3) of the basic body (1) and passing through the water channel for acting in the grinding contact region to create complete cooling of the face. During operation of the present invention, deformation of the grinding face is small, the face can be quickly cooled, and chip removal is fast. The present invention is applicable to fast and high speed machining, and the machining quality of the surface of the workpiece is improved, sharpness of the grinding wheel is maintained and the service life is prolonged.