Porous Abrasive Article with Integrated Bonding
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Solution Overview
Problem
The construction industry faces challenges in forming abrasive tools with improved performance and efficiency, as existing methods for bonding abrasive segments to cores are inefficient and do not fully utilize the potential of advanced materials for reduced friction and enhanced grinding capabilities.
Innovation Solution
The development of an abrasive article comprising a body with a bond matrix, abrasive particles, and an interconnected phase, where the body includes a specific content and structure of metal bond material, abrasive particles, and porosity to reduce contact surfaces and friction, allowing for improved grinding performance and lower power consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional bonding methods (sintering, brazing, welding) are used to attach abrasive segments to cores, then the abrasive tools can be formed, but the formation process is inefficient and complex
Solution Approach 1:
The patent combines the abrasive segment formation and core attachment processes into a single integrated operation. The abrasive mixture is applied directly to the core and cured in one step, eliminating the need for separate sintering, brazing, or welding operations. This merging of processes directly addresses the inefficiency and complexity of traditional multi-step bonding methods.
Solution Approach 2:
The patent applies the abrasive mixture to the core in its uncured state before final curing, allowing for direct formation and attachment. This preliminary application step enables the abrasive material to be positioned and shaped on the core before the bonding process completes, streamlining the overall formation process and eliminating subsequent bonding operations.
2Productivity
If conventional abrasive tools with larger contact surfaces are used, then material removal can be performed, but friction and power consumption increase
Solution Approach 1:
The patent creates a porous structure within the abrasive segment by incorporating voids or pores in the cured resin matrix. This porous structure reduces the actual contact surface area between the abrasive tool and the workpiece while maintaining effective cutting edges. The reduced contact area directly lowers friction and power consumption during material removal operations.
3Ease of manufacture
If abrasive segments are formed individually and then bonded, then the abrasive tool can be assembled, but the process is time-consuming and inefficient
Solution Approach 1:
The patent merges the abrasive segment formation and core attachment into a single integrated process. Instead of forming segments separately and then bonding them, the mixture is applied directly to the core and cured in one operation. This eliminates the time required for separate formation and bonding steps while maintaining manufacturing simplicity.
Solution Approach 2:
The patent maintains the segmented structure of the abrasive tool for ease of assembly and replacement, but changes how the segments are formed and attached. Each segment can still be applied as a discrete layer to the core, preserving the modular advantage while eliminating the time-consuming bonding process through direct curing.
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 abrasive article achieves reduced friction and improved grinding performance with lower power consumption, enhancing the efficiency and effectiveness of material removal operations such as grinding, drilling, and cutting.
Implementation Method 1
curing the resin mixture to form a solid segment
Data Source
AI summary
An abrasive article can include an abrasive component including a body. The body can include a bond matrix and abrasive particles contained in the bond matrix. In an embodiment, the body can include an interconnected phase extending through at least a portion of the bond matrix. The body can include a discontinuous phase including a plurality of discrete members. At least one of the discrete member can include a macroscopic pore. In another embodiment, the body can include a porosity of at least 15 vol % for a total volume of the body.