Grinding Tool Segments With Peripheral Cutting to Prevent Digging
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Solution Overview
Problem
Conventional grinding tools for soft to medium-hard building materials often dig into the surface, leading to inconsistent machining, increased dynamic loads, noise, vibration, and wear, especially when working on walls and ceilings where contact pressure is not constant.
Innovation Solution
The tool segment features a base body with hard material cutting elements on both the front and peripheral sides, including a raised web as a spacer to limit penetration depth, and a grinding tool design that incorporates multiple such segments, allowing for smoother machining by lateral cutting elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional grinding tools with hard material cutting elements are used to achieve high stock removal rates, then productivity is improved, but the tool tends to dig into the surface causing inconsistent machining and increased dynamic loads
Solution Approach 1:
The grinding tool is divided into multiple tool segments arranged around the circumference, with each segment equipped with cutting elements. This segmentation allows different portions of the tool to engage with the workpiece at different positions, distributing the cutting action and preventing any single point from digging in excessively, thereby maintaining machining consistency while preserving high stock removal rates.
Solution Approach 2:
Tool segments are equipped with cutting elements specifically on their front and peripheral sides, creating localized cutting zones. The front-side cutting elements perform axial cutting while peripheral cutting elements perform lateral cutting, creating different cutting characteristics at different locations to prevent digging in and ensure consistent machining across the entire tool surface.
2Productivity
If the tool segment has cutting elements on the front side for effective material removal, then productivity is improved, but the tool may dig deeply and become stuck in place
Solution Approach 1:
Cutting elements are added not only on the front side (axial direction) but also on the peripheral sides (radial direction) of the tool segments. This multi-dimensional cutting capability allows the tool to engage with the workpiece from multiple directions, preventing the tool from digging deeply in a single axial direction and becoming stuck, while maintaining high material removal efficiency.
Solution Approach 2:
The tool segment design changes the geometric parameters by adding peripheral cutting elements with specific orientations. The peripheral cutting elements are oriented to perform lateral cutting movements, changing the cutting parameter from purely axial to a combination of axial and lateral movements, which prevents the tool from becoming stuck while maintaining productivity.
3Productivity
If hard material cutting elements are used to process soft to medium-hard building materials, then productivity is improved, but noise and vibration levels increase
Solution Approach 1:
The grinding tool is segmented into multiple tool segments distributed around the circumference, with each segment performing a portion of the cutting action. This segmentation distributes the cutting load across multiple segments rather than concentrating it at a single point, reducing the impact forces that generate noise and vibration while maintaining high productivity through the collective cutting capability of all segments.
Solution Approach 2:
Multiple tool segments are arranged to ensure continuous cutting action around the entire circumference of the grinding tool. As the tool rotates, different segments continuously engage with the workpiece, providing uninterrupted material removal. This continuous action smooths out the cutting process and reduces the intermittent impacts that cause noise and vibration, while maintaining high machining speed.
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 high stock removal rates with reduced jerking and impact loads, ensuring uniform processing and minimizing tool digging, resulting in a smoother surface finish and reduced wear.
Implementation Method 1
the base body has, on the at least one circumferential side equipped with the cutting element, a raised web in a cutting direction behind the at least one cutting element, which web serves as a spacer for limiting a penetration depth
Implementation Method 2
the front side is equipped with at least one hard material cutting element
Implementation Method 3
at least one circumferential side of the circumferential region is equipped with at least one hard material cutting element
Data Source
Figure 1~2
Figure 3~4
Figure 5~10
AI summary
A tool segment (60) for a grinding tool for surface finishing of building materials has a base body (110) with an end face (112), a rear face (114) facing away from the end face (112), and a circumferential region (122) extending between the end face (112) and the rear face (114). The end face (112) is equipped with at least one hard material cutting element (140, 142). The rear face (114) has at least one fastening element (130) for mounting on a base body of a grinding tool. At least one circumferential side (124) of the circumferential region (122) is equipped with at least one hard material cutting element (150). A grinding tool has at least one such tool segment (60). A grinding machine for surface finishing of building materials has at least one such grinding tool.