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 breakage due to harsh grooving environments, 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 longevity, and mounted on a hub with carriers for increased durability and ease of assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If diamond blades are used for pavement grooving and grinding, then the tool can perform the cutting function, but the feed rate is low and the lifespan is short
Solution Approach 1:
The invention changes the geometric parameters of the PDC tip by adding a double chamfer structure. This parameter modification enhances the impact resistance of the PDC tip, allowing it to withstand harsh grooving environments better, thereby extending tool lifespan while maintaining high feed rates
Solution Approach 2:
The invention uses a composite structure combining PDC (polycrystalline diamond compact) material with a steel body. The PDC tip provides extreme hardness and wear resistance for high feed rates, while the steel body provides structural support and toughness, creating a composite tool that achieves both high productivity and extended lifespan
2Strength
If PDC segments are used in harsh grooving environments with high impact loading, then the tool can maintain structural integrity, but fatigue cracks initiate and tips break off
Solution Approach 1:
The double chamfer is added to the PDC tip in advance during manufacturing, before the tool enters service. This preliminary structural reinforcement creates compressive stresses and geometric features that counteract the impact loads and fatigue cracks that will occur during operation, preventing tip breakage before it happens
Solution Approach 2:
The double chamfer structure acts as a cushioning feature that absorbs and distributes impact energy before it can cause damage to the PDC tip. The chamfer geometry provides a stress distribution pattern that cushions against the high impact loading inherent in grooving operations, preventing fatigue crack initiation
3Strength
If PDC segments are strongly attached to the steel body through high frequency brazing, then the joint strength is high, but the manufacturing process becomes more complex
Solution Approach 1:
The invention replaces mechanical attachment methods (such as screws or rivets) with high frequency brazing, which uses thermal energy to create a metallurgical bond between the PDC segment and steel body. This substitution achieves superior joint strength while the modular carrier design maintains ease of assembly and disassembly at the wheel level
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 provides higher feed rates, extended tool life, and simplified mounting/unmounting processes, enhancing the efficiency and cost-effectiveness of pavement grooving and grinding operations.
Implementation Method 1
A double chamfer added to the surface of PDC tip with laser cutting machine
Implementation Method 2
Modified PDC is then strongly attached to the body of steel through the method of high frequency brazing
Data Source
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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.