Polymer Core Abrasive Wheel for Edge Grinding
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Solution Overview
Problem
Existing abrasive wheels for edge grinding have limitations in terms of mechanical strength, wearability, and manufacturing efficiency, particularly due to the use of heavy metal cores and unresolved issues in edge grinding tools.
Innovation Solution
An abrasive article featuring a core made of polymer material with reinforcing fibers, having a heat deflection temperature of at least 130°C and a shrinkage ratio of not greater than 3%, which is injection molded around a bonded abrasive body to form an integrally bonded abrasive article with improved mechanical properties and manufacturing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a heavy metal core is used in abrasive wheels, then mechanical strength is improved, but weight increases
Solution Approach 1:
The patent changes the material parameters by using polymer composites with specific formulations (polymer matrix with fiber reinforcements) to achieve high strength-to-weight ratio, replacing traditional metal cores while maintaining mechanical strength
Solution Approach 2:
The patent employs composite materials consisting of polymer matrices combined with reinforcing fibers (such as glass fibers, carbon fibers, or aramid fibers) to create a core that provides both lightweight properties and enhanced mechanical strength, resolving the contradiction between weight reduction and strength maintenance
2Weight of moving object
If polymer material is used for the core, then weight is reduced, but heat deflection temperature decreases
Solution Approach 1:
The patent uses composite materials where polymer matrices are combined with heat-resistant fiber reinforcements (such as glass fibers, carbon fibers, or ceramic fibers) to maintain structural integrity at elevated temperatures while keeping the core lightweight
Solution Approach 2:
The patent modifies the thermal parameters by selecting polymers with high heat deflection temperatures and incorporating thermally stable additives or fillers to ensure the core can withstand grinding temperatures without deforming
3Ease of manufacture
If traditional manufacturing methods are used, then manufacturing process is simple, but manufacturing efficiency decreases
Solution Approach 1:
The patent combines the core and abrasive segments into a single integrated manufacturing process using injection molding, where the polymer core is molded directly around pre-formed abrasive segments, eliminating separate assembly steps and improving manufacturing efficiency
Solution Approach 2:
The patent prepares abrasive segments in advance with appropriate bonding surfaces, then incorporates them into the injection molding process for the core, allowing parallel processing and reducing overall manufacturing time while maintaining process simplicity
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 polymer-based core provides a lightweight abrasive wheel with enhanced mechanical strength and wearability, and the manufacturing process improves efficiency and performance in edge grinding applications.
Implementation Method 1
the core comprises a polymer material and reinforcing fibers, the reinforcing fibers having an average aspect ratio of length to width ranging from at least 10 to not greater than 5000
Implementation Method 2
a method of making an abrasive wheel comprises inserting a bonded abrasive body into a mold and injection molding a core around at least a portion of the bonded abrasive body
Data Source
AI summary
An abrasive article in form of an abrasive wheel comprising a core and a bonded abrasive body disposed within an interior recess of a peripheral surface of a core. The core comprises a polymer material and has an HDT at 0.45 MPa of at least about 130° C., and a low shrinkage ratio.