Grinding Worm With Seamless Abrasive Transition for Joint-Free Reliability
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Solution Overview
Problem
Existing grinding worms with multiple abrasive grain sizes are complex to manufacture and prone to defects at the joint between modules, leading to reliability issues during grinding and dressing.
Innovation Solution
A grinding worm with two sections of different abrasive grains embedded in the same matrix material, forming a seamless transition and eliminating the need for separate modules, allowing for cost-effective production and enhanced robustness throughout its service life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate grinding worm modules with different abrasive grains are joined together, then different grain sizes can be provided in one grinding worm, but the joint between modules represents a weak point leading to defects during use and dressing
Solution Approach 1:
The patent combines multiple abrasive grain sizes into a single integral grinding worm body manufactured by primary molding, eliminating the need for separate modules and their joints. This merging approach maintains the versatility of having different grain sizes while removing the reliability issue of joint defects.
Solution Approach 2:
The patent segments the abrasive grain distribution within a single homogeneous matrix material, creating zones with different abrasive grain sizes (coarse in first section, fine in second section) without creating physical module joints. This segmentation is achieved through controlled distribution during primary molding rather than assembly of separate parts.
2Adaptability or versatility
If separate grinding worm modules are manufactured and joined together, then grinding worms with different grain sizes can be created, but the manufacturing process becomes complex
Solution Approach 1:
The patent merges the manufacturing of different abrasive grain sections into a single primary molding process, eliminating the complexity of manufacturing, handling, and assembling multiple separate modules. The homogeneous matrix material allows all abrasive grains to be incorporated in one casting operation.
Solution Approach 2:
The single grinding worm body performs multiple functions (rough grinding with coarse grains, finish grinding with fine grains) that previously required separate specialized modules. This universal design simplifies manufacturing while maintaining the capability to perform different grinding operations.
3Adaptability or versatility
If separate grinding worm modules are joined together, then different abrasive grains can be provided, but production costs increase
Solution Approach 1:
The patent combines all abrasive grain incorporation into a single primary molding process, eliminating the need for separate manufacturing, quality control, and assembly operations for multiple modules. This consolidation reduces labor, equipment, and time costs while maintaining the versatility of different grain sizes.
Data Source
AI summary
A grinding worm being a dressable grinding worm, wherein a first section of the grinding worm has a first abrasive grain which is incorporated in a matrix material and wherein a second section of the grinding worm has second abrasive grain which is incorporated in the matrix material. The first abrasive grain and the second abrasive grain differ from one another in terms of grain size and/or grain material. A transition section is formed between the first section and the second section, in which both the first abrasive grin and the second abrasive grain are incorporated in fie matrix material, wherein the first section, the second section and the transition section have the same matrix material and wherein an intermixing of the first abrasive grain and the second abrasive grain is formed at least in sections in the transition section.