Rotary Dresser With Variable Diameter Roll For Uniform Grain Action
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Solution Overview
Problem
Rotary dressers with fixed diamond abrasive grain distribution on a roll's outer circumference lead to uneven dressing resistance and increased local wear, causing shape accuracy issues due to varying numbers of abrasive grains acting on the grinding wheel during rotation.
Innovation Solution
A rotary dresser design with a roll having an outer surface featuring cylindrical portions and a concave arc portion of varying diameters, ensuring a fixed number of diamond abrasive grains in the circumferential direction at any axial position, maintaining consistent dressing resistance and reducing local wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If diamond abrasive grains are arranged spirally at a predetermined interval on the outer circumferential surface of a roll, then the distribution density of diamond abrasive grains per area is fixed, but the number of diamond abrasive grains acting on the grinding wheel per rotation varies at different axial positions, causing uneven dressing resistance and local wear
Solution Approach 1:
The patent applies local quality by varying the distribution density of diamond abrasive grains at different axial positions on the roll. Specifically, the distribution density is made smaller at both axial end portions and larger at the axial center portion, so that the number of diamond abrasive grains acting on the grinding wheel per rotation is substantially equal across all axial positions. This resolves the contradiction by locally adjusting grain density to achieve uniform dressing resistance throughout the roll length.
2Quantity of substance
If the number of diamond abrasive grains in the circumferential direction is increased at portions with large circumferential length, then the distribution density per area is maintained, but the dressing resistance increases and grinding burns are liable to be generated
Solution Approach 1:
The patent applies local quality by making the distribution density of diamond abrasive grains smaller at the axial end portions where the circumferential length is larger. This ensures that even though more grains are present in the circumferential direction at these portions, the reduced density prevents excessive dressing resistance and grinding burns, while maintaining uniform grain action across the roll length.
3Force
If the number of diamond abrasive grains in the circumferential direction is decreased at portions with small circumferential length, then the dressing resistance is reduced, but the diamond abrasive grains become larger in wear and local wear or abrasion occurs
Solution Approach 1:
The patent applies local quality by making the distribution density of diamond abrasive grains larger at the axial center portion where the circumferential length is smaller. This ensures that sufficient numbers of grains act on the grinding wheel at these portions, preventing excessive wear and local abrasion, while the increased density compensates for the smaller circumferential length.
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
This design maintains shape accuracy over a long term by reducing dressing resistance and suppressing local wear of diamond abrasive grains, ensuring consistent action on the grinding wheel.
Implementation Method 1
a rotary dresser having diamond abrasive grains arranged on an outer circumference of a roll
Data Source
Figure 1~2
Figure 3~4
Figure 5~6(B)
AI summary
A rotary dresser (10) is provided with a roll (11) having an outer circumferential surface which includes an arc portion (11c, 211c) or inclined portion (111a, 111b) differing in diameter in dependence on the axial position thereof, and a plurality of diamond abrasive grains (12) embedded on the outer circumferential surface of the roll (11). The number of the diamond abrasive grains (12) in the circumferential direction is fixed even at any axial position on the outer circumferential surface of the roll (11).