Electroplated Outer Blade Cutting Wheel for Rare Earth Magnet Machining
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Solution Overview
Problem
Current outer-diameter blade cutting wheels for rare earth sintered magnets face limitations in achieving high-speed and high-accuracy cutting while maintaining low cutting resistance and cost-effectiveness.
Innovation Solution
The method involves forming the blade section with widthwise side portions that include channels extending from the inner to the outer perimeter, and using a metal bond electroplating process to bond abrasive grains onto a cemented carbide base, with a mesh member and jig segments that define a cavity for efficient abrasive grain placement and plating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the blade thickness is reduced to improve manufacturing yield and machining speed, then productivity is improved, but the blade becomes more prone to deformation under cutting force
Solution Approach 1:
The patent uses cemented carbide (a composite material of WC particles and Co/Ni binder) for the blade base instead of traditional alloy tool steel or high-speed steel. Cemented carbide has a Young's modulus of 450-700 GPa compared to 200 GPa for iron alloy materials, providing significantly higher rigidity that allows thin-blade construction without sacrificing strength. This enables the blade to be thinned for improved productivity while maintaining resistance to deformation under cutting forces.
2Productivity
If the cutting speed is accelerated to improve productivity, then manufacturing efficiency is improved, but the cutting resistance and heat generation increase
Solution Approach 1:
The patent changes the material parameter (Young's modulus) by using cemented carbide instead of traditional steel materials. This parameter change allows the blade to maintain high rigidity at reduced thickness, which in turn reduces overall cutting resistance while enabling higher cutting speeds. The high rigidity minimizes blade deflection during cutting, allowing for accelerated feed rates without increasing cutting resistance per unit area.
3Ease of manufacture
If traditional alloy tool steel or high-speed steel is used for the blade base, then manufacturing cost is reduced, but the blade cannot be thinned and machining accuracy deteriorates
Solution Approach 1:
The patent employs cemented carbide as the blade base material, replacing traditional alloy tool steel or high-speed steel. While cemented carbide may have higher material cost, it enables blade thinning that improves manufacturing yield and allows for higher precision cutting. The high rigidity of cemented carbide ensures that even thin blades maintain dimensional stability and cutting accuracy, offsetting the material cost through improved yield and reduced waste.
4Productivity
If multiple blades are assembled to increase productivity, then the number of pieces cut per time is increased, but the total cutting resistance on the blade assembly increases
Solution Approach 1:
The patent uses cemented carbide for the blade base, providing high rigidity that allows each individual blade to be thinner and experience less cutting resistance. When multiple such low-resistance blades are assembled together, the total cutting resistance on the multi-blade assembly remains lower than if traditional thicker steel blades were used. This enables increased productivity through multiple blades while keeping the total force requirement manageable for motors of identical power.
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-speed and high-accuracy cutoff machining with reduced cutting load and improved yield, achieving enhanced productivity and cost reduction.
Implementation Method 1
bonding diamond or CBN abrasive grains thereto by metal or resin bonding
Data Source
Figure 1A~1B
Figure 2A~2C
Figure 3A~3B
AI summary
An outer blade cutting wheel includes an annular thin disc base (1) and a blade section (2) of bonded abrasive grains formed on the periphery of the base. The blade section includes widthwise side portions each of which is provided with channels (21) extending from an inner perimeter to an outer perimeter of the blade section. The cutting wheel is made by an electroplating method in which jig segments (51) applied to the base disc have flanges (51a) which define a cavity (c) for the abrasive grains and bond metal and also have protrusions (511) for forming the channels.