Rare Earth Magnet Cutting Jig With Guide Grooves
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Solution Overview
Problem
Existing methods for cutoff machining of rare earth magnet blocks using outer-diameter blades face challenges such as deformation, dimensional inaccuracy, and reduced productivity due to mechanical strength issues of steel cores and inadequate cutting fluid supply, leading to glazing, loading, and chipping.
Innovation Solution
A jig assembly with guide grooves and a cutting fluid feed nozzle having slits is used to securely position and effectively feed cutting fluid to the blades, restricting axial run-out and ensuring accurate and efficient machining by entraining fluid on the blade edges, even with a smaller volume of cutting fluid.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If a thin OD blade with steel core is used to minimize cutting part width, then material yield is improved, but the blade deforms or bows during machining due to insufficient mechanical strength
Solution Approach 1:
The patent applies composite materials by bonding diamond abrasive grains to a thin disk core, creating a composite structure that combines the sharpness and cutting ability of diamond with the structural support of the disk core. This allows the blade to be thin for minimal material waste while maintaining sufficient strength through the composite construction.
Solution Approach 2:
The patent applies local quality by concentrating the abrasive cutting function only at the outer peripheral rim of the disk core, while the core itself remains thin and lightweight. This localized application of abrasive material allows the cutting edge to be sharp and effective while minimizing the overall blade thickness and material usage.
2Loss of substance
If cutting fluid supply is reduced to minimize waste, then environmental impact is improved, but glazing, loading, and chipping occur during machining
Solution Approach 1:
The patent introduces air as an intermediary substance that mixes with cutting fluid to create a foamy cutting fluid. This foam structure increases the surface area of cutting fluid contact with the cutting zone, improving cooling and lubrication efficiency while using less actual cutting fluid volume.
Solution Approach 2:
The patent utilizes phase transition by introducing air bubbles into cutting fluid, creating a foam structure that transitions between liquid and gas phases. This foam form of cutting fluid provides better penetration and distribution at the cutting zone while reducing the overall volume of cutting fluid required.
3Productivity
If multiple blades are mounted coaxially to increase productivity, then output is improved, but adequate cutting fluid supply to each blade becomes difficult
Solution Approach 1:
The patent uses air as an intermediary to deliver cutting fluid to multiple coaxially mounted blades. The air stream carries cutting fluid along the axial direction, enabling simultaneous supply to multiple blades without requiring separate fluid delivery systems for each blade.
Solution Approach 2:
The patent segments the cutting fluid supply by introducing it at multiple axial positions along the blade assembly, with air streams distributing the fluid to different blade levels. This segmented approach ensures each blade receives adequate cooling and lubrication despite the compact coaxial arrangement.
4Strength
If alloy tool steel core is used for OD blade, then material cost and mechanical strength are improved, but the core deforms or bows during cutoff machining of hard materials
Solution Approach 1:
The patent uses composite materials by bonding diamond abrasive grains to the steel core, creating a composite blade structure. The diamond provides extreme hardness for cutting hard materials while the steel core provides structural support, together preventing deformation during machining.
Solution Approach 2:
The patent changes the physical parameters of the blade by using a thin disk core design with optimized thickness and diameter ratios. This parameter optimization allows the blade to be lightweight and easy to rotate while maintaining sufficient stiffness through the composite construction and proper geometric proportions.
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
This approach enables high-accuracy and high-speed cutoff machining of rare earth magnet blocks by effectively delivering cutting fluid to the machining points, reducing deformation and improving productivity while minimizing material waste.
Implementation Method 1
feeding a cutting fluid into the feed nozzle through the inlet and injecting the cutting fluid through the slits... the cutting fluid reaching the slits and coming in contact with the outer peripheral portion of each cutoff abrasive blade is entrained on surfaces of the cutoff abrasive blade being rotated
Implementation Method 2
a diamond grinding wheel outer-diameter (OD) blade having diamond grits bonded to an outer periphery of a thin disk as a core
Data Source
AI summary
Apparatus and methods for multiple cut-off machining of rare earth magnet blocks are described. The cutting is by a plurality of abrasive blades (11) mounted coaxially on a rotating shaft. The rare earth magnet block (m) is fixed for cutting using a jig assembly comprising a pair of jig segments (31) which clamp the block. The jig segments have guide grooves (31a) on their surfaces, which restrict axial run-out of the cutting blades and also hold cutting fluid, which is entrained on the blade surfaces as they run through the guide grooves. Cutting fluid may be fed from a feed nozzle (2) having a plurality of slits (21) in which the edges of the respective blades are inserted.