Intersecting Plate Abrasive Particles for Rake Angle Control
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Solution Overview
Problem
Existing abrasive particles, particularly triangular and intersecting plate-shaped ones, face challenges in controlling rake angle, density, and adhesion in abrasive articles, leading to suboptimal performance and wear characteristics.
Innovation Solution
The development of intersecting plate-shaped abrasive particles, where a first plate is integrally joined to a second plate at a predetermined angle, allowing precise control of the rake angle and improved adhesion, and the formation of channels for swarf removal and cooling fluid conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If triangular shaped abrasive particles are used to enhance cut rates, then cutting performance is improved, but control over rake angle and adhesion is difficult
Solution Approach 1:
The abrasive particle is divided into two distinct plate sections: a base plate for adhesion and a cutting plate for abrasion. This segmentation allows each section to be optimized independently - the base plate provides a large surface area for secure bonding while the cutting plate maintains a precise rake angle for effective material removal, resolving the contradiction between cut rate and rake angle control
Solution Approach 2:
The invention transitions from traditional three-dimensional triangular particles to a two-dimensional intersecting plate configuration. This dimensional change enables precise control of the rake angle in the cutting plane while the base plate extends in a perpendicular dimension to provide stable adhesion, simultaneously achieving high cut rates and precise angular control
2Productivity
If shaped abrasive particles are used to control performance, then abrasion performance is improved, but adhesion in nonwoven structures is reduced
Solution Approach 1:
By separating the particle into a base plate and cutting plate, the invention dedicates the entire base plate surface to adhesion functions. This large, flat base plate provides maximum contact area with nonwoven fibers, ensuring reliable retention while the cutting plate maintains optimized geometry for abrasion performance, resolving the contradiction between abrasion performance and adhesion
3Productivity
If vertices contact the workpiece frequently, then grinding efficiency is increased, but flat surfaces increase bearing area and wear
Solution Approach 1:
Instead of designing particles where flat surfaces contact the workpiece (traditional approach), the invention inverts the design so that vertices and edges of the cutting plate contact the workpiece. This inversion increases grinding efficiency through point contact while the limited size of the cutting plate prevents excessive bearing area formation, simultaneously achieving high productivity and extended abrasive life
Data Source
Figure 1A~2B
Figure 3A~4B
Figure 5~7
AI summary
Shaped abrasive particles comprising a ceramic and comprising a first plate integrally joined to a second plate at a predetermined angleß.