Segmented Abrading Tool Islands Reduce Friction Heat
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Solution Overview
Problem
Conventional abrading tools face issues with friction and heat generation due to large continuous tool surfaces, and they tend to clog with swarf, leading to inefficiencies in material removal processes.
Innovation Solution
An abrading tool with a metal base member featuring raised islands spaced apart, where only the tip portions are coated with a composite abrasive material comprising diamond, cubic boron nitride, tungsten carbide, or titanium carbide, allowing swarf to flow through the gaps between the islands, reducing clogging and improving efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a large continuous abrading surface is used, then the abrading area is increased, but friction and heat generation increase
Solution Approach 1:
The continuous abrading surface is segmented into multiple discrete raised islands spaced apart from each other. This segmentation reduces the total contact area between the tool and workpiece, thereby reducing friction and heat generation while maintaining an effective abrading surface area through the distributed islands.
2Area of stationary object
If a large continuous abrading surface is used, then the abrading area is increased, but swarf accumulation and clogging increase
Solution Approach 1:
The abrading surface is divided into separate raised islands with gaps between them. These gaps create open pathways that allow swarf to flow away from the abrading surface, preventing accumulation and clogging while maintaining sufficient abrading area through the distributed island structure.
Solution Approach 2:
The abrading surface structure incorporates open spaces between the raised islands, creating a porous-like configuration that permits swarf to pass through and escape. This open pathway structure prevents clogging while maintaining effective abrading capability.
3Area of stationary object
If abrasive material is applied to the entire surface, then coverage is maximized, but cost and material usage increase
Solution Approach 1:
Abrasive material is applied only to the raised islands rather than the entire surface. This localized application concentrates the abrasive material where it is most needed for effective abrading, reducing overall material usage and cost while maintaining adequate coverage for the abrading function.
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 tool design enhances durability and cost-effectiveness by minimizing swarf accumulation and heat generation, enabling improved abrading performance with reduced tool surface resistance.
Implementation Method 1
the composite abrasive material is applied either by electrodeposition or by electroless deposition
Implementation Method 2
the composite abrasive material is applied either by electrodeposition or by electroless deposition
Data Source
AI summary
An abrading tool includes a base member having a support portion defining a first level, and a plurality of integral raised islands extending upwardly above the first level. The base member may be formed of metal or a non-conductive material. The islands are spaced apart from one another. Each island includes a respective tip portion. The distance between adjacent islands may be greater than the width of a single island. An abrasive composite material, including a carrier material and particles of an abrasive material, is affixed to the tip portions of at least some of the islands. The abrasive material may be applied by electroplating, electro-less plating, brazing or another method. The abrasive material is applied only to the tip portion of the islands, such that the first level of the support portion is substantially free of the abrasive material. Methods of making the abrading tool are also described.