Machining Segment Green Compact With Protruding Hard Particles
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for producing machining segments require special press dies for each defined particle pattern, limiting their versatility and efficiency, especially in dry machining of concrete materials where abrasive concrete slurry is absent, leading to rapid dulling of hard aggregate particles and reduced machining rate.
Innovation Solution
A method involving a sequence of steps to produce a green compact using conventional tools, where hard particles are embedded in a support material different from the matrix material, allowing for the use of conventional press dies in compaction and further processing, enabling protrusions of hard particles on the surface for improved dry machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a special press die with recesses is used to produce green compacts with protruding hard particles, then the machining rate in dry conditions is improved, but the device complexity and manufacturing cost increase due to requiring different dies for each particle pattern
Solution Approach 1:
Instead of creating recesses in the press die to form protrusions, the invention inverts the approach by creating protrusions on the press die surface that form recesses in the green compact. This allows conventional press dies to be used while still achieving the desired protruding hard particles after compaction, resolving the contradiction between improved machining rate and reduced device complexity
Solution Approach 2:
The invention changes the geometric parameters of the press die surface from recesses to protrusions, and changes the compaction process parameters to achieve the desired particle arrangement. This parameter transformation allows using conventional press dies while still producing green compacts suitable for dry machining applications
2Ease of manufacture
If conventional press dies are used for compaction, then the manufacturing cost is reduced, but the hard particles cannot protrude on the surface for improved dry machining
Solution Approach 1:
The invention performs preliminary arrangement of hard particles on the support material before compaction, positioning them in specific patterns. This preliminary action ensures that after compaction with conventional press dies, the hard particles protrude on the surface, enabling both cost-effective manufacturing and improved dry machining performance
Solution Approach 2:
The invention introduces a support material as an intermediary between the hard particles and the matrix material. This support material enables the hard particles to be arranged in defined patterns and to protrude after compaction, while still allowing the use of conventional press dies, thus resolving the contradiction between manufacturing cost and machining rate
3Device complexity
If hard particles are embedded in the matrix material, then the green compact structure is simplified, but the machining rate decreases in dry conditions due to lack of protruding particles
Solution Approach 1:
The invention segments the green compact structure into three distinct components: support material, hard particles, and matrix material. This segmentation allows the hard particles to protrude on the surface for improved dry machining while maintaining a structured and organized green compact that can be manufactured with conventional tools
Solution Approach 2:
The invention applies local quality by creating different regions within the green compact: areas with protruding hard particles for machining and areas with embedded particles for structural support. This local differentiation enables the compact to serve multiple functions, resolving the contradiction between structural simplicity and machining performance
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
Enables the production of machining segments with protruding hard particles using conventional tools, enhancing machining rate and efficiency in dry conditions by embedding hard particles in a support material that remains intact or infiltrates during sintering, facilitating the use of conventional press dies.
Implementation Method 1
facilitating the use of conventional press dies
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3~4
AI summary
The invention relates to a method for producing a green body for a machining segment (51) from a pulverulent or granular first matrix material (56) and first hard material particles (57), the machining segment being connected with a bottom side (61) to a green body of a machining tool. The machining segment (51) has at an upper side (62), which lies opposite to the bottom side (61), a projection (Δ) of the first hard material particles (57).