Multi-Layer Abrasive Tool Production via Screen Printing
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Solution Overview
Problem
Current manufacturing processes for abrasive tools with ordered cutting particles are complex, costly, and limited by geometric restrictions, making it difficult to achieve reproducible and efficient cutting particle positioning.
Innovation Solution
A multi-layered tool production process using screen printing to define recesses in a primary layer, followed by stencil printing of abrasive particles and a final heat treatment with an organic binder system to fix the particles, allowing for precise and flexible positioning of abrasive particles in three-dimensional space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If cold pressing process is used to manufacture cutting tool with ordered diamonds, then cutting particles can be arranged in defined positions, but geometric resolution in xy and z directions is significantly limited
Solution Approach 1:
The manufacturing process is divided into separate functional steps: screen printing for creating the binder layer and defining recesses, stencil printing for positioning abrasive particles, and selective filling for incorporating particles into specific recesses. This segmentation allows each step to be optimized independently, achieving high positioning precision without requiring the entire system to achieve complex geometric resolution simultaneously.
Solution Approach 2:
The organic binder system acts as an intermediary that temporarily holds the abrasive particles in defined positions during the manufacturing process. The binder layer created by screen printing provides a matrix that receives and positions particles through stencil printing, then the selective filling process incorporates particles into recesses. This intermediary binder system enables precise particle arrangement without requiring the final tool structure itself to achieve high geometric resolution.
2Manufacturing precision
If known manufacturing processes are used for abrasive tools with ordered cutting particles, then cutting particles can be positioned, but production complexity increases and production costs rise
Solution Approach 1:
The process merges screen printing technology with stencil printing technology to achieve both efficient production and high precision. Screen printing efficiently creates the binder layer and recess structures, while stencil printing efficiently positions the abrasive particles. This combination allows for mass production of tools with ordered cutting particles, resolving the contradiction between production efficiency and positioning accuracy.
Solution Approach 2:
The method changes the physical state and application parameters of the organic binder system from a traditional metal bonding approach to a screen-printable paste formulation. This parameter change enables the binder to be applied precisely where needed through screen printing, then modified through stencil printing, and finally activated through selective filling and heat treatment. This parameter change allows high-precision particle positioning while maintaining production efficiency.
3Manufacturing precision
If conventional methods are used, then abrasive particles can be incorporated, but reproducible and repeatedly defined cutting particle overlap cannot be generated
Solution Approach 1:
The screen printing process creates the binder layer and defines the recess geometry in advance, establishing a reproducible template for particle placement. The stencil printing then uses this pre-defined template to position abrasive particles consistently. This preliminary action of creating the binder layer and recess structure before particle incorporation ensures that the same particle arrangement can be repeatedly generated with high precision and reliability.
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 abrasive tools with tight positioning dimensions and adjustable structures, achieving higher abrasive particle concentration and efficient cutting performance by allowing for defined and reproducible particle arrangements.
Implementation Method 1
the tool is obtained through a final heat treatment of the green part
Implementation Method 2
The final heat treatment removes the organic binder system, which preferably contains polymer binders and additives
Data Source
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AI summary
The present invention relates to a method for producing a multi-layer tool, in which a green part is produced by screen printing a primary layer (1) provided with recesses (2) from a primary material containing an organic binder system, and subsequently abrasive particles (3) are introduced into the recesses (2) by stencil printing, and then a secondary layer (7) or a top layer (6) from the primary material containing the organic binder system is applied by screen printing to fix the abrasive particles (3) in the recesses (2). The tool is obtained by a final heat treatment of the green part. Multi-dimensional tools with any desired arrangement of the abrasive particles (3) can be produced by repeating the described steps.