Abrasive Articles with Segmented Vitreous and Organic Bonds
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Solution Overview
Problem
Current abrasive tools lack the capability to efficiently perform both coarse and fine grinding operations at high speeds, particularly in applications like gear grinding, due to limitations in burst speed and operational stability.
Innovation Solution
The development of abrasive articles with multiple portions, including a first abrasive portion with a vitreous bond material, a second abrasive portion with an organic bond material, and an interior portion, which are coupled to achieve a higher burst speed and improved mechanical properties, allowing for efficient coarse and fine grinding operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a single abrasive portion is used, then the structure is simple, but the burst speed and mechanical properties are insufficient for high-speed applications
Solution Approach 1:
The abrasive article is divided into multiple distinct abrasive portions (first abrasive portion with vitreous bond, second abrasive portion with organic bond) coupled together. This segmentation allows each portion to contribute different mechanical properties and burst speed characteristics, achieving higher overall burst speed while managing structural complexity through modular design
Solution Approach 2:
The invention uses composite construction by coupling different abrasive portions made from different bond materials (vitreous and organic). This composite approach combines the high burst speed capability of vitreous bond with the flexibility and shock absorption of organic bond, achieving superior mechanical properties for high-speed applications
2Productivity
If a single abrasive portion is used, then the manufacturing process is simple, but both coarse and fine grinding operations cannot be efficiently performed
Solution Approach 1:
The abrasive article is designed with multiple abrasive portions that can perform different grinding functions (coarse and fine grinding) within a single tool. This multi-functionality allows the article to efficiently perform both coarse material removal and fine surface finishing operations, increasing productivity while the coupled portion design enables standardized manufacturing processes
3Productivity
If high burst speed is achieved through multiple portions, then grinding efficiency improves, but the device complexity increases
Solution Approach 1:
By segmenting the abrasive article into multiple specialized portions coupled together, each portion can be optimized for specific grinding tasks (coarse vs. fine grinding). This segmentation enables high grinding efficiency through functional specialization while the modular coupled structure allows for systematic manufacturing and assembly processes
Solution Approach 2:
Different abrasive portions are assigned different local qualities based on their intended function: the first abrasive portion with vitreous bond is optimized for coarse grinding with high burst speed, while the second abrasive portion with organic bond is optimized for fine grinding with flexibility. This local quality differentiation achieves high overall grinding efficiency while each portion can be manufactured using appropriate processes for its specific requirements
Data Source
AI summary
An abrasive article can include a body including a plurality of portions including a first abrasive portion and a second abrasive portion. The first abrasive portion can include a vitreous bond material and abrasive particles contained within the bond material. The second abrasive particles can include an organic bond material and abrasive particles contained within the bond material. The body can have a burst speed of at least 65 m/s. In an embodiment, the abrasive article can include an interior portion coupled to the first and second abrasive portions. In another embodiment, the interior portion can optionally include abrasive particles or a filler material.