Incomplete Polyhedral Abrasive Particles for Adhesion and Shelling
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Solution Overview
Problem
Existing abrasive particles and articles face challenges in cost, performance, and lifespan, particularly in terms of adhesion, mineral breakdown, and burning during use, with solid polygonal shapes often leading to shelling and loading issues.
Innovation Solution
The development of incomplete shaped abrasive particles, such as tetrahedral and polyhedral particles, formed from molds with predetermined shapes, which offer improved adhesion, reduced shelling, and the ability to incorporate grinding aids like lubricants, enhancing performance and lifespan.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If solid polygonal shaped abrasive particles are used, then the abrasive article provides initial cutting ability, but the particles exhibit shelling and reduced adhesion during use
Solution Approach 1:
The abrasive particle is segmented into an incomplete polyhedral shape with open interior space, dividing the solid structure into regions that improve adhesion while maintaining cutting ability. The segmentation creates arms extending from a vertex that provide multiple attachment points to the backing, reducing shelling during use.
2Quantity of substance
If complete polyhedral shaped particles are used, then the particles maintain structural integrity, but the interior space cannot be utilized for grinding aids
Solution Approach 1:
The invention extracts the interior material from the complete polyhedral shape, creating an incomplete structure with open interior space. This extraction removes the constraint of solid filling, allowing the interior volume to be utilized for incorporating grinding aids and lubricants while maintaining the external polyhedral shape for cutting performance.
Solution Approach 2:
The incomplete polyhedral particle creates a porous or hollow structure with open interior space that can accommodate grinding aids. The porous configuration allows lubricants and grinding aids to be incorporated within the particle structure, providing sustained release during abrasive operations.
3Reliability
If incomplete shaped abrasive particles are used, then adhesion is improved and shelling is reduced, but the manufacturing process becomes more complex
Solution Approach 1:
The incomplete polyhedral shape introduces asymmetry by removing portions of the complete polyhedron, creating an asymmetric structure with open interior space. This asymmetric configuration improves adhesion by providing irregular surfaces and multiple attachment points while the mold complexity is managed through selective removal of material rather than complex additive manufacturing.
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
Incomplete shaped abrasive particles provide improved adhesion, reduced shelling, controlled mineral breakdown, and the ability to incorporate grinding aids, leading to enhanced performance and cost-effectiveness in abrasive applications.
Implementation Method 1
drying the abrasive particle precursor to form the incomplete shaped abrasive particle
Data Source
AI summary
Various embodiments disclosed relate to an incomplete shaped abrasive particle, articles containing the same, and methods of manufacture.