PDC Grinding Wheel with Double-Chamfered Tips for Impact Resistance
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Solution Overview
Problem
Diamond blades used for pavement grooving and grinding have low feed rates and short lifespans, and PDC tools face fatigue cracks and detachment issues under harsh conditions, leading to high costs and inefficiencies.
Innovation Solution
A PDC segment with a double chamfered tip, enhanced by laser cutting, is brazed to a steel body for improved impact resistance, and mounted on a grinding wheel with T- and L-shaped carriers for structural integrity, allowing for higher feed rates and simplified mounting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If diamond blades are used for pavement grooving and grinding, then cutting capability is achieved, but feed rate is low and lifespan is short
Solution Approach 1:
The patent changes the material parameter from diamond to PDC (polycrystalline diamond compact) and modifies the geometric parameter by adding a double chamfer to the tip. This combination achieves both higher feed rates and extended lifespan, resolving the contradiction between productivity and duration of action.
Solution Approach 2:
The patent uses composite material structure by combining PDC (polycrystalline diamond compact) with a steel body. The PDC tip provides wear resistance and cutting capability while the steel body provides structural strength, achieving both high productivity and long lifespan.
2Productivity
If PDC segments are used in harsh grooving environment, then cutting performance is improved, but fatigue cracks initiate and tips break off
Solution Approach 1:
The patent modifies the geometric parameter by adding a double chamfer to the PDC tip, which changes the stress distribution and eliminates stress concentration points. This prevents fatigue crack initiation while maintaining cutting performance, resolving the contradiction between productivity and reliability.
Solution Approach 2:
The patent converts the potential harm of impact loading into a benefit by designing the double chamfer geometry that redirects impact forces away from the PDC-steel interface, preventing fatigue cracks while maintaining the ability to handle harsh grooving conditions.
3Duration of action of moving object
If PDC segments are attached to steel body, then tool longevity is extended, but mounting and unmounting procedures are complex
Solution Approach 1:
The patent divides the tool into separable segments (PDC tips and steel bodies) that can be independently replaced. The standardized interface with mounting holes and set screws allows individual PDC segments to be quickly changed without replacing the entire tool, achieving both longevity and ease of operation.
Solution Approach 2:
The patent creates a dynamic mounting system where the set screw can be easily tightened and loosened to secure or release PDC segments. This simple mechanical dynamic connection allows rapid replacement of wear components while maintaining a robust permanent attachment during operation.
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
The solution extends PDC tool longevity, enhances impact resistance, and simplifies mounting, resulting in increased efficiency and cost-effectiveness compared to traditional methods.
Implementation Method 1
A double chamfer added to the surface of PDC tip with laser cutting machine further increases the longevity of the tool by enhancing impact resistance of PDC and a PDC segment as a whole
Implementation Method 2
Modified PDC is then strongly attached to the body of steel through the method of high frequency brazing
Data Source
AI summary
The present invention provides a grinding wheel product which removes various construction materials such as concrete, asphalt, thermoplastic, traffic markings, lines or signal on the street or highway through rotating motion.