Runner Disc Surface Contact Angle for Double-Sided Machining
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Solution Overview
Problem
Conventional runner discs in double-sided machining centers cause significant rounding of workpiece edges and excessive wear, despite existing solutions like DLC coatings and hydrophilic surfaces failing to provide sufficient wear resistance and edge geometry improvement.
Innovation Solution
The surface of the runner disc is designed with a contact angle of 70° to 75° for a water droplet, achieved through mechanical roughening or DLC coating, to ensure a homogeneous machining fluid distribution, minimizing edge rounding and wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional runner discs are used, then machining can be performed, but significant rounding of workpiece edges occurs and excessive wear happens
Solution Approach 1:
The invention changes the surface energy parameter of the runner disc by controlling the contact angle of water droplets to be between 100° and 110°. This parameter change modifies the interaction between the machining fluid and the runner disc surface, resulting in improved fluid distribution that reduces edge rounding and minimizes wear, thereby simultaneously improving manufacturing precision and reliability
Solution Approach 2:
The invention applies a diamond-like carbon (DLC) coating to the runner disc surface. This composite material approach combines the base runner disc material with the DLC coating layer, creating a surface with specific tribological properties that reduce friction and wear while maintaining the required mechanical strength, thus improving both wear resistance and edge geometry
2Reliability
If DLC coating is applied to increase wear resistance, then wear resistance improves, but edge geometry is not sufficiently improved
Solution Approach 1:
The invention optimizes the contact angle parameter to a specific range of 100° to 110°, which is more precise than conventional approaches. This optimized parameter ensures optimal distribution of machining fluid across the workpiece surface, including at the edges, thereby achieving both improved wear resistance through DLC coating and sufficiently improved edge geometry through controlled fluid distribution
3Manufacturing precision
If hydrophilic surface is created to improve edge geometry, then edge geometry improves, but wear resistance is not sufficiently increased
Solution Approach 1:
The invention combines DLC coating material with controlled surface energy characteristics to create a composite surface that exhibits both wear resistance and optimal fluid distribution. The DLC coating provides the wear-resistant foundation while the controlled contact angle (100°-110°) ensures proper machining fluid distribution for good edge geometry, achieving both requirements simultaneously
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 enhances workpiece edge geometry and reduces rotor disc wear, leading to improved machining results and extended service life.
Implementation Method 1
The surface of the runner disc has a contact angle of a water droplet of at least 70° and not more than 75°
Data Source
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AI summary
The invention relates to a runner disc for guiding workpieces in a double-sided machining machine, comprising at least one workpiece opening for receiving at least one workpiece to be machined on both sides by material removal in the double-sided machining machine, wherein the surface of the runner disc has a contact angle of a water droplet of at least 60°. The invention further relates to a double-sided machining machine and a method for machining a workpiece.